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Bryan Boilers FREE FLEX FF1000 Installation & Operation Manual

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Free Flex I&O manual
P/N 105641-01
For service and repair to the boiler, call your heating contractor. When seeking information on the boiler from the
manufacturer, provide boiler model and serial number as shown on the rating label.
Boiler Model:
Installation Date:
Heating Contractor:
Address:
!
WA R NING
This manual must only be used by a qualified heating installer/service
technician. Read all instructions in this manual before installing. Perform
steps in the order given. Failure to comply could result in severe
personal injury, death, or substantial property damage.
Bryan Steam, LLC
Phone: 765-473-6651
FREE FLEX
High Efficiency, Low Emission
CONDENSING BOILER
INSTALLATION & OPERATION MANUAL
A
S
M
E
H
783 N Chili Ave, Peru, IN 46970
Serial Number:
Type System:
Phone/Email:
Form: 2435
Revision: 11
Date: 10/01/2021
www.bryanboilers.com
sales@bryansteam.com

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  • Page 1 Free Flex I&O manual Form: 2435 P/N 105641-01 Revision: 11 FREE FLEX Date: 10/01/2021 High Efficiency, Low Emission CONDENSING BOILER INSTALLATION & OPERATION MANUAL For service and repair to the boiler, call your heating contractor. When seeking information on the boiler from the manufacturer, provide boiler model and serial number as shown on the rating label.

  • Page 2: Table Of Contents

    Table of Contents I. Introduction Testing Controls and Safety Devices Important Information Ignition Failure VIII. Service, Maintenance, and Inspection Disclaimers and Local Codes General Maintenance Test and Inspections Component Description (See Figure 1 to Figure Daily Weekly II. Pre-Installation Monthly Installation Conformance Annually Boiler Foundation Ignition Assembly Cleaning Clearance and Serviceability Burner Assembly Cleaning III. Installation Heat Exchanger Cleaning Receiving the Boiler Tube Replacement Procedure Boiler Water and Condensate Connections Safety and Operating Controls...
  • Page 3 Table of Figures I. Introduction Figure 1: FF1000 External Boiler Connections Figure 2: FF1500-3000 External Boiler Connections Figure 3: FF3500-6000 External Boiler Connections II. Pre-Installation Figure 4: Clearances and Serviceability III. Installation Figure 5: Condensate Drain Figure 6: Condensate Assembly Orientation IV. Venting V. Requirements VI. Before Operation VII. System Start-Up Figure 8: Siemens Valves Figure 7: High Fire Adjustment on Main Gas Valve (FF1000-FF3000) VIII. Service, Maintenance, and Inspection Figure 9: Ignition Assembly Figure 10: Panel Removal in Preparation for Tube Inspection - FF1000 Figure 11: Panel Removal in Preparation for Tube Inspection - FF1500-FF3000 Figure 12: Panel Removal in Preparation for Tube Inspection - FF3000-FF6000 Figure 13: Tube Puller Insertion Appendix A: Sizing Gas Piping Appendix B: Vent and Combustion Air Pressure Drop Data Appendix C: Installation &...
  • Page 4 Table of Tables I. Introduction Table 1: Water Flow Switch Settings II. Pre-Installation Table 2: Clearances and Serviceability III. Installation Table 3: Typical Condensate Flow Rate IV. Venting Table 4: Combustion Air and Flue Gas Requirements V. Requirements Table 5: Electrical Requirements Table 6: Gas Supply Requirements Table 7: Sound Pressure Levels Table 8: Minimum Water Flow Rates for Variable Primary Pumping Table 9: Maximum Water Flow Rate for Variable Primary Pumping Table 10: Water Flow Rates for Primary/Secondary Pumping at 20°F ΔT Table 11: Water Flow Rates for Primary/Secondary Pumping at 40°F ΔT Table 12: Water Flow Rates for Constant Volume Primary Pumping Table 13: GPM Increase for Glycol System VI. Before Operation Table 14: Chemical Agents and Effects Table 15: Recommended Feed Water Limits VII. System Start-Up Table 16: Siemens Nominal Low Fire O2 Table 17: Safety Device Tests VIII. Service, Maintenance, and Inspection Table 18: Safety and Operating Controls Table 19: General Troubleshooting Appendix A: Sizing Gas Piping Table 20: Maximum Gas Capacity Of Schedule 40 Pipe Table 21: Equivalent Lengths Of Standard Pipe Fittings And Valves Table 22: Specific Gravity Correction Factors Appendix B: Vent and Combustion Air Pressure Drop Data...

  • Page 5: Introduction

    I. Introduction B. Disclaimers and Local Codes A. Important Information Installation must conform to the requirements of The following terms are used throughout this the authority having jurisdiction. In the absence of manual to bring attention to the presence of hazards such requirements, installation must conform to the of various risk levels, or to important information National Fuel Gas Code, NFPA 54/ANSI Z223.1, and/ concerning product life. It is critical that all personnel or CAN/CGA B149 Installation Codes. Where required read and follow all the information provided in the by the authority having jurisdiction, the installation boxes marked DANGER, WARNING, CAUTION, and must conform to the Standard for Controls and Safety NOTICE.

  • Page 6: Test And Inspections

    C. Test and Inspections Upon the completion of boiler installation, final air- 5. Pressure relief valve. The pressure relief fuel adjustments are to be made by factory trained protects the heat exchanger from an over- service personnel. The emissions data and the O2 pressure condition. levels at minimum and maximum input rate can be 6. Ducted combustion air flange. found on the back side of the front-boiler’s door, 7. Flue gas vent outlet.

  • Page 7: Figure 1: Ff1000 External Boiler Connections

    References 16 to 18 are only used on FF3500 – FF6000 16. Boiler Hand/Off/Auto 17. Push Button Display. The display provides easy access for viewing and adjusting boiler operational parameters and provides alarm/ lockout codes. 18. Temperature Display. Provides for temperature set points and actual temperature. Figure 2: FF1500-3000 External Boiler Connections Figure 1: FF1000 External Boiler Connections...

  • Page 8: Pre-Installation

    II. Pre-Installation B. Boiler Foundation The customer should examine the equipment for any damage. It is the responsibility of the installer Before uncrating, the boiler location should be to ensure all parts supplied with the equipment are prepared. The boiler should set upon a good level fitted in a correct and safe manner. concrete floor. If the boiler is not level or the floor is not in good condition, a concrete foundation should be built, the dimensions being larger than the outside WARNING dimensions of the boiler base.

  • Page 9: Figure 4: Clearances And Serviceability

    Flue Gas Vent Boiler Boiler Figure 4: Clearances and Serviceability Table 2: Clearances and Serviceability 1500- 3500- Description 1000 3000 6000 Clearance Above Top of Boiler 6” 6” 6” Front of Boiler – Burner End 24” 32” 43” From Chimney or Vent Collector 18”...

  • Page 10: Installation

    III. Installation NOTICE A. Receiving the Boiler If the relief valve discharges periodically, this may be The boiler is shipped from the factory with (4) shipping due to thermal expansion in a closed water supply feet/legs bolted to the skids. These are provided to system. Contact the water supplier or local plumbing facilitate unloading/moving with a forklift. Lifting inspector on how to correct this situation. DO NOT points are also provided to enable over-head lifting PLUG THIS RELIEF VALVE.

  • Page 11: Condensate Trap/Drain Assembly

    c. A common condensate pump/sump may C. Condensate Trap/Drain Assembly be used. Run separate piping from each 1. The condensate trap/drain assembly, must be condensate drain to the sump. A common Installed to the outlet in the rear of the boiler. drain may be used to discharge condensate a.

  • Page 12: Gas Supply Connections

    D. Gas Supply Connections E. Combustion Air Supply System The installation must conform completely to the For proper combustion it is necessary to provide the requirements of the authority having jurisdiction, or boiler room with appropriate openings for fresh air in the absence of such, requirements shall conform in supply. Temporary air intakes such as windows and the U.S. to the current National Fuel Gas Code, ANSI doors should be avoided since they may be closed. Z223.1-1984, or in Canada to the current Natural gas In addition to air needed for combustion, sufficient and propane installation code (CAN/CSA B149.1-05),...
  • Page 13 1. Two Permanent Opening Method d. If the combustion air is provided by a buildings mechanical ventilation system, the a. One opening starting within 12” of the top system shall be sized to provide the specified of the boiler room and one starting within combustion air in addition to the ventilation 12” of the bottom of the boiler room shall air requirements. be provided. The openings shall be open directly to the outside or ducted directly to 4.
  • Page 14 e. Ducts shall not serve both upper and lower combustion air openings where both such openings are used. The separation between ducts serving the upper and lower combustion air openings shall be maintained to the source of combustion air. f. Ducts shall not be screened where terminating in an attic space. g. Horizontal upper combustion air ducts shall not slope downward toward the source of combustion air. h. For informational purposes, there are several codes that address the amount of air and/or size of the opening(s) in walls for combustion air.

  • Page 15: Venting

    IV. Venting 8. Vent pipe system must be adequately supported In order to properly vent this boiler, the installer at intervals no less than five (5) feet apart. The must select and install a venting system that meets completed vent system must be rigid and able all requirements specified in this section, as well as to withstand impacts without collapse. following the instructions provided by the venting system manufacturer. 9. The boiler’s venting is Category IV (positive vent pressure, flue condensing), with regards to the A.

  • Page 16: Category Ii Venting

    17. Install fire-stops where vent passes through WARNING floors, ceilings or framed walls. The fire-stop Do not use a barometric damper with this boiler. must close the opening between the vent pipe This is a positive pressure system. The use of a and the structure. barometric damper may cause flue gases to leak 18. Enclose vent passing through occupied or into the boiler room.

  • Page 17: Massachusetts

    Table 4: Combustion Air and Flue Gas 1. INSTALLATION OF CARBON MONOXIDE Requirements DETECTORS: At the time of installation of the side wall venting gas fueled equipment, the Flue gas Comb. air installing plumber or gasfitter shall observe that Boiler flow, ACFM req. SCFM Flue Size Model @40% XSA @40% XSA a hard wired carbon monoxide detector with 200°F 0°F an alarm and battery back-up is installed on the...

  • Page 18: Venting Requirements For Canada

    4. INSPECTION. The state or local gas inspector ii. The “special venting systems” shall be of the side wall horizontally vented gas fueled Product Approved by the Board, and the equipment shall not approve the installation instructions for the system shall include unless, upon inspections, the inspector a parts list and detailed installation observes carbon monoxide detectors and...
  • Page 19 b. Combustion Air: For combustion air where 4. Appliance Venting per CAN/CSA-B149.1-05 the air supply is provided by natural airflow a. Paragraph 8.9 of CAN/CSA-B149.1-05 from outdoors, in addition to the opening addresses “Appliance Venting”. Paragraphs for ventilation air, there shall be permanent 8.9 through 8.31 address many facets of flue opening having a total cross-sectional free gas vents, many of which do not apply to area of not less than 1 in2 for each 30,000 the this boiler, which is a Category IV listed BTU/hr. (70 mm2 for each kW) of the total appliance requiring the use of special venting...

  • Page 20: Requirements

    V. Requirements Connect field supplied safety limits or devices using E. Electrical proper terminals provided in boiler electrical cabinet. WARNING Refer to wiring diagram supplied with boiler for wiring information. All electrical connections must conform to the National Electrical Code, ANSI / NFPA 70 and/or See Appendix H for sample-wiring diagrams. An as-built wiring diagram is included with every boiler CSA C22.1 Electrical Code and all other State and when it ships. Contact a Bryan Steam Representative...

  • Page 21: Sound Pressure Levels

    G. Sound Pressure Levels 1. Water Flow Rates (Variable Primary Pumping Systems) Sound pressure levels were measured at 4-1/2’ above a. Variable primary pumping systems shall the floor and 3’ from the boiler at the front, rear and be capable of delivering no less than the two sides. See Table 7 for decibel readings. minimum and no more than the maximum Table 7: Sound Pressure Levels specified in Table 8 and Table 9 for each boiler Decibel Levels connected in the system.

  • Page 22: Table 10: Water Flow Rates For Primary/Secondary Pumping At 20°F Δt

    2. Water Flow Rates (Primary/Secondary Systems) Table 12: Water Flow Rates for Constant Volume Primary Pumping a. Each boiler connected to a secondary loop of a primary / secondary pumping system Maximum Flow Rate shall have a constant volume pump sized in Model High Fire Δ...

  • Page 23: Before Operation

    VI. Before Operation The boil out of the boiler and system is neither difficult A. Pre-Boil Out Flushing of System nor expensive. The chemicals needed for cleaning Much of the dirt and contamination in a new hot are readily available. Tri-sodium phosphate and water system can be flushed out before the boil out sodium hydroxide (lye) are the most commonly used of the system. First, flush the system of waste with chemicals. Be certain the chemicals used contain clear water. The boiler and circulating pumps must be NO CHLORIDES. Use only one type of solution in isolated through the successive zones of the system...

  • Page 24: Boiler Water Treatment

    Failure to properly clean the system or to install E. Boiler Water Treatment mechanical sediment removal equipment can result Water treatment is required for satisfactory operation in tube blockage and severe corrosion plus damage of the boiler. It must be devised to prevent depositing to pumps, controls, and air removal devices. of scale and corrosion from acids, oxygen and other Inspect, repair as necessary, or replace system air such harmful elements that may be in the water control devices.

  • Page 25: Table 14: Chemical Agents And Effects

    a. Water treatment should be checked and CAUTION maintained according to Table 15 whenever Bryan Steam Standard Warranty does not cover the boiler is operating. The boiler operator problems caused by oxygen contamination of boiler should be sure that the boiler is not operating water. for long periods without proper water Bryan Steam Standard Warranty does not cover treatment. problems caused by scale build-up. b.

  • Page 26: System Start-Up

    VII. System Start-Up B. System Check 1. Verify that the venting, water piping, gas piping and electrical system are installed properly. WARNING Refer to installation instructions contained in this manual. Completely read, understand and follow all instructions in this manual, Concert Boiler Control 2. Confirm all electrical, water and gas supplies manual, and all other component manuals supplied are turned off at the source and the chimney/ with this boiler before attempting start- up. vent is clear of obstructions. If boiler is controlled by an external control system, this system must be temporarily disconnected. A.

  • Page 27: Commissioning Ff1000 - Ff3000

    6. Increase the high gas pressure switch setting DANGER to 14” w.c. Failure to properly adjust excess air will result in 7. Cycle the boiler. The boiler should lockout on unsafe levels of carbon monoxide. Variations in flame failure or ignition failure. (Boiler may venting or combustion air pressure and temperature recycle once if there was an ignition failure.

  • Page 28: Table 16: Siemens Nominal Low Fire O2

    20. O level must be set at high fire with all jacket iv. Turn adjustment screw counter clockwise , a doors installed and front cabinet door closed. maximum of 1/4 turn, to decrease gas flow. (increases O2 level). Then allow to stabilize. a. DUNGS - High Fire O levels are adjusted with the gas shutter valve located on the outlet of v. Replace brass hex cover. the gas valve (Figure 7). i. Turn adjustment screw toward the Plus (+) WARNING side to increase gas flow (decrease O level).

  • Page 29: Finish Commissioning The Boiler (Ff1000-Ff3000)

    H. Finish Commissioning the Boiler (FF1000-FF3000) Reconnect any wires from the external control system, if applicable. 1. Perform an operation test of the external control system. 2. Place system control back in normal operation, if necessary. 3. Place the boiler into automatic mode. Menu > Operation > Auto/Manual Rate Control > Automatic (76 password required) Throttle Screw for High Fire Adjustment I.

  • Page 30: Testing Controls And Safety Devices

    K. Testing Controls and Safety Devices Prior to placing the boiler in operation, the installing contractor or other responsible personnel must perform safety and control device limit tests to ensure proper operation of the appliance. Refer to Table 17 for recommended method(s) of carrying out these safety limit devices tests. Table 17: Safety Device Tests After Lockout Component Test Method(s) Actual Alarm Message Annunciation Manually reset the Concert Close the manual gas valve High Gas Pressure Boiler Control and switch.

  • Page 31: Service, Maintenance, And Inspection

    VIII. Service, Maintenance, and Inspection WARNING A. General Maintenance Assure that all safety and operating controls and 1. Follow any checks and/or inspections that may components are operating properly before placing be required as specified in the component boiler back in service. manufacturers’ instruction manuals. 2. Repair or replace any defective components immediately. WARNING 3.

  • Page 32: Weekly

    C. Weekly 4. Inspect the ceramic insulator for cracks, and if necessary, replace the igniter. After each 1. Check combustion safety controls for flame inspection of the igniter, replace gasket and failure (or other alarm messages). apply anti-seize compound to mounting screws 2. Check all limit controls and low water cutoff as prior to reinstalling them. described above.

  • Page 33: Heat Exchanger Cleaning

    H. Heat Exchanger Cleaning c. Sledgehammer (steel head, approximately 3 lb) 1. Perform visual inspection of both boiler flue passes, and remove any debris from the surfaces of the heat exchanger. 2. If necessary, brush the tubes of the heat exchanger using non-abrasive, non-metallic bristle brush.

  • Page 34: Figure 10: Panel Removal In Preparation For Tube Inspection - Ff1000

    ITEM # DESCRIPTION JACKET SIDE PANEL CENTER RAIL FLUE DOOR CLAMPS CONVECTION DOOR FURNACE DOOR TUBE CLAMPS Figure 10: Panel Removal in Preparation for Tube Inspection - FF1000 ITEM # DESCRIPTION JACKET SIDE PANEL FLUE DOOR CLAMPS FURNACE DOOR TUBE CLAMPS Figure 11: Panel Removal in Preparation for Tube Inspection - FF1500-FF3000 Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...

  • Page 35: Figure 12: Panel Removal In Preparation For Tube Inspection - Ff3000-Ff6000

    ITEM # DESCRIPTION JACKET SIDE PANEL FLUE DOOR CLAMPS FURNACE DOOR TUBE CLAMPS Figure 12: Panel Removal in Preparation for Tube Inspection - FF3000-FF6000 Note: Tubes are accessed and serviced from both sides of the FF3500-FF600 Boilers. (Right side exploded view not shown.) 3.

  • Page 36: Figure 13: Tube Puller Insertion

    Figure 13: Tube Puller Insertion 7. Prepare the headers and replacement tubes. Before placing a new tube into the header, clean the holes by wiping gently with emery cloth to be sure that there are no burrs. Clean the replacement tube-ends of any rust or debris. With a small brush, apply a thin coating of gray pipe dope around the inside of the hole. Pipe dope may also be applied to the tube-end. Cutting oil may be mixed with the pipe dope for easier application. 8. Insert both ends of the tubes into the headers. Insert the lower tube-end into the bottom header first. Then insert the top tube-end into the top header. Insert all replacement tubes before driving them. 9.

  • Page 37: Safety And Operating Controls

    CAUTION Do Not Overdrive Tubes! Overdriving tubes can cause damage to the tubes and boiler header holes. Use only approved Bryan Steam tube driver and specified hammer. The end-formed tube fitting is designed to deform if overdriven to minimize damage to the vessel tube holes. 10. Reinstall the tube clamps. Replace the nuts and flat washers if damaged in any way. Use brass nuts only! Tighten the nuts until snug. Do not try to compress the tube-ends into the holes with the clamps, because the clamps might break or the stud might shear. 11. Refill the boiler. Fill the unit with water and ensure that there is no leakage at the replacement tube-ends before reinstalling the flue collector panels. WARNING If a leak is detected after a replacement tube has been installed, pressure in the boiler must be reduced to zero before adjusting tube(s). Adjusting tubes under pressure could result in serious personal injury. 12. Reinstall all flue access doors, door clamps, and jacket panels. 13. Perform startup check prior to putting boiler back into operation. J. Safety and Operating Controls All of the safety control devices listed in Table 18 are logically linked to the Concert Boiler Control that supervises the sequence of operation of the boiler for safe and efficient operation. It does so by ensuring proper light off and firing of the main burner and if need be, will immediately cut-off gas supply to the main burner when gas...

  • Page 38: Troubleshooting

    Table 18: Safety and Operating Controls Component Function If this switch is in the off position, power is interrupted to the control circuit of the boiler, which Power Switch prevents the boiler from operating. If the switch is in the on position, power is supplied to the control circuit.

  • Page 39: Table 19: General Troubleshooting

    Table 19: General Troubleshooting INDICATION POSSIBLE CAUSE CORRECTIVE ACTION Boiler is not responding to a call Boiler is not seeing Enable/ Check wiring for loose connections or wiring errors. If Domestic for heat, “Status” and “Priority” Disable of Domestic Demand is expected check the DHW Demand/Modulation is show “Standby”.

  • Page 40: Appendix A: Sizing Gas Piping

    Appendix A: Sizing Gas Piping Design the gas piping system to provide an adequate gas supply to the boiler. Refer to Table 6 for minimum and maximum gas supply pressures and boiler capacities. Also consider existing and expected future gas utilizing equipment (i.e., water heater, cooling equipment). Refer to Table 20 for maximum capacity of schedule 40 pipe. Table 21 lists equivalent pipe length for standard fittings. Given the specific gravity of gas at the boiler’s location, a correction factor can be found on Table 22 and multiplied by the “Capacity in Cubic Feet of Gas Per Hour” in Table 20. For gas piping material other than schedule 40 pipes, refer to the National Fuel Gas Code, NFPA 54/ANZI Z223.1 and/or CAN/CGA B149 Installation codes. Use methods and materials in accordance with Local Codes and requirements of gas supplier. In the absence of such requirement follow National Fuel Gas Codes, NFPA /ANSI Z 223.1 and/or CAN/CGA B149 Installation Codes. Table 20: Maximum Gas Capacity Of Schedule 40 Pipe Pipe Length Pipe Size (NPT) in Equivalent ¾ 1-1/4 1-1/2 2-1/2 Feet 1060 1580 3050 4860 8580 17500 1090 2090 3340 5900...

  • Page 41: Table 21: Equivalent Lengths Of Standard Pipe Fittings And Valves

    Table 21: Equivalent Lengths Of Standard Pipe Fittings And Valves Valves Fully Open (Screwed, Schedule 40, Screwed Fittings Flanged, Welded) Pipe Size 90 deg. Tee, ID(in.) (NPT) Swing 90 deg. Elbow 45 deg. Elbow Flow Through Gate Globe Angle Check Branch (threaded) (threaded) (threaded)

  • Page 42: Appendix B: Vent And Combustion Air Pressure Drop Data

    Appendix B: Vent and Combustion Air Pressure Drop Data The combined pressure drop through the vent and combustion air duct shall not exceed 100 equivalent feet. Use the tables below to calculate the pressure drop in the vent / combustion air system. Table 23: Vent Pressure Drop Data Flue Vent Straight Length (eq 90° Elbow (eq ft) 45° Elbow (eq ft) Velocity (fpm) Diameter (in.) ft/ft) FF1000 Pressure Drop in Equivalent Feet (Flue Vent) 1534 2.22 1.11...

  • Page 43: Table 24: Combustion Air Pressure Drop Data

    Table 24: Combustion Air Pressure Drop Data Flue Vent Straight Length (eq 90° Elbow (eq ft) 45° Elbow (eq ft) Velocity (fpm) Diameter (in.) ft/ft) FF1000 Pressure Drop in Equivalent Feet (Combustion Air Duct) 6.25 3.13 1121 1.32 .658 FF1500 Pressure Drop in Equivalent Feet (Combustion Air Duct) 3.03 1.49 FF2000 Pressure Drop in Equivalent Feet (Combustion Air Duct)

  • Page 44: Appendix C: Installation & Startup Report

    Appendix C: Installation & Startup Report Form 2443 P/N: 105641-06 Revision 1 9/29/2021 Boiler Installation & Startup Report Customer: __________________________________________ Date: _____________ Address: ______________________ City: _______________ State: ______ Zip: _______ Contact: ___________________________ Phone: ____________________________ ===================================================================== Model _______________________ S/N _______________ Input Rating _________________ □...

  • Page 45: Appendix D: Venting Diagrams

    Appendix D: Venting Diagrams Figure 14: Typical Horizontal Vent Piping Figure 15: Typical Vertical Pressurized Venting Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...

  • Page 46: Appendix E: Combustion Air Diagrams

    Appendix E: Combustion Air Diagrams Figure 16: Typical Horizontal Air Intake Piping Figure 17: Typical Vertical Air Intake Piping Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...

  • Page 47: Appendix F: Boiler Piping Diagrams

    Appendix F: Boiler Piping Diagrams Figure 18: Single Boiler, Primary / Secondary 4D Max Inlet/Return Air Vent Purge Valve 1000 model shown. Isolation Valve Inlet/Outlet Connections are different on the 1500- 6000 models. System Circulator Boiler Circulator Outlet/Supply Makeup Water Check Valve Check Valve Y-Strainer Pressure Reducing Valve...

  • Page 48: Figure 19: Multiple Boilers, Primary Reverse-Return Piping

    Figure 19: Multiple Boilers, Primary Reverse-Return Piping Outlet/Supply System Circulator Pressure Reducing Valve Check Valve Makeup Water Isolation Valve Check Valve 1000 model shown. Inlet/Outlet Connections Air Vent are different on the 1500- 6000 models. Expansion Tank Motorized Isolation Valve Inlet/Return Y-Strainer System Circulator Outlet/Supply...

  • Page 49: Figure 20: Multiple Boilers, Primary / Secondary Reverse Return Piping

    Figure 20: Multiple Boilers, Primary / Secondary Reverse Return Piping Air Vent 4D Max Purge Valve System Pump Inlet/Return Expansion Tank 1000 model shown. Outlet/Supply Inlet/Outlet Connections are different on the 1500- Makeup Water 6000 models. Pressure Reducing Valve Isolation Valve Isolation Valve Boiler Pump Check Valve...

  • Page 50: Figure 21: Multiple Boilers, Primary / Secondary Piping

    Figure 21: Multiple Boilers, Primary / Secondary Piping 4D Max 1000 model shown. Inlet/Outlet Connections Inlet/Return Air Vent are different on the 1500- 6000 models. Expansion Tank Purge Valve Isolation Valve System Circulator Outlet/Supply Makeup Water Check Valve Pressure Reducing Valve Boiler Circulator Check Valve Y-Strainer...

  • Page 51: Figure 22: Multiple Boilers, Primary / Secondary With Indirect Water Heater

    Figure 22: Multiple Boilers, Primary / Secondary With Indirect Water Heater Inlet/Return Air Vent 1000 model shown. Inlet/Outlet Connections Pressure Reducing Valve are different on the 1500- Purge Valve 4D Max 6000 models. Expansion Tank Check Valve Makeup Water DHW Circulator System Circulator Outlet/Supply Indirect DHW Heater...

  • Page 52: Appendix G: Water Flow Pressure Drops

    Appendix G: Water Flow Pressure Drops Free Flex 1000 Free Flex 1500 Free Flex 2000 Delta T Ft. Hd. Delta T Ft. Hd. Delta T Ft. Hd. 100F 0.51 100F 0.37 100F 0.65 0.63 0.45 0.80 0.79 0.58 1.02 1.04 0.75 1.33 1.41 1.02...
  • Page 53 This Page Intentionally Left Blank Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...

  • Page 54: Appendix H: Wiring Diagrams

    Appendix H: Wiring Diagrams Note: Wiring diagrams are for reference only, please refer to the wiring shipped with the boiler for accuracy Figure 23: FF1000 Wiring Diagram Page 1-A Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...
  • Page 55 Page 1-B Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...

  • Page 56: Figure 24: Ff1500 To Ff3000 115 Vac Single Phase Wiring Diagram

    Figure 24: FF1500 To FF3000 115 VAC Single Phase Wiring Diagram Note: Wiring diagrams are for reference only, please refer to the wiring shipped with the boiler for accuracy Page 1-A Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...
  • Page 57 Page 1-B Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...

  • Page 58: Figure 25: Ff1500 To Ff3000 208 - 230 Vac Single Phase Wiring Diagram

    Figure 25: FF1500 To FF3000 208 – 230 VAC Single Phase Wiring Diagram Note: Wiring diagrams are for reference only, please refer to the wiring shipped with the boiler for accuracy Page 1-A Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...
  • Page 59 Page 1-B Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...

  • Page 60: Figure 26: Ff2000 To Ff3000 208-460 Vac Three Phase Wiring Diagram

    Figure 26: FF2000 To FF3000 208-460 VAC Three Phase Wiring Diagram Note: Wiring diagrams are for reference only, please refer to the wiring shipped with the boiler for accuracy Page 1-A Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...
  • Page 61 Page 1-B Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...

  • Page 62: Figure 27: Ff3500 To Ff6000 208-460 Vac Three Phase Wiring Diagram

    Figure 27: FF3500 To FF6000 208-460 VAC Three Phase Wiring Diagram Note: Wiring diagrams are for reference only, please refer to the wiring shipped with the boiler for accuracy Page 1-A Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...
  • Page 63 Page 1-B Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...
  • Page 64 Page 2-A Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...
  • Page 65 Page 2-B Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...
  • Page 66 Notes Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com Phone: 765-473-6651 Fax: 765-473-3074 Email: sales@bryansteam.com...
  • Page 67 Bryan Steam (seller) Limited Warranty LIFETIME THERMAL SHOCK WARRANTY A. Incidental, special or consequential damages, such as loss of the use of products, facilities or production, inconvenience, loss of time or Subject to the terms and conditions herein, Seller warrants to the origi- labor expense involved in repairing or replacing the alleged defective nal owner at the original installation site that the boiler pressure vessel Product.
  • Page 68 Bryan Steam, LLC Peru, IN 46970 Phone: 765-473-6651 Inquiry@bryansteam.com www.bryanboilers.com...

This manual is also suitable for:

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