Bryan Boilers BFIT 1000 Installation, Operation And Maintenance Manual
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Bryan Boilers BFIT 1000 Installation, Operation And Maintenance Manual

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Condensing with the Power to FIT
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
Heating Boiler Models
BFIT 1000
BFIT 1250
BFIT 1500
BFIT 2000
Model: ______________________________________________
Serial Number: ______________________________________________
Installation Date: ______________________________________________
: __________________________________________
Heating Contractor
Bryan Steam, LLC
Phone: 765-473-6651
Hot Water Supply
Boiler Models
BFIT 2500
BFITW 2500
BFIT 3000
BFITW 3000
BFIT 3500
BFITW 3500
BFIT 4000
BFITW 4000
783 N. Chili Avenue, Peru, IN 46970
Save this manual for future reference.
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable 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 neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
PN: 108588-02
REV. 10
www.bryanboilers.com
inquiry@bryansteam.com

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Summary of Contents for Bryan Boilers BFIT 1000

  • Page 1 • Do not try to light any appliance. Hot Water Supply • Do not touch any electrical switch; do Heating Boiler Models Boiler Models not use any phone in your building. BFIT 1000 BFIT 2500 BFITW 2500 • Immediately call your gas supplier BFIT 1250 BFIT 3000 BFITW 3000 from a neighbor’s phone.

  • Page 2: Table Of Contents

    Table of Contents I. Hazard Definitions II. Read Before Proceeding Local Codes Warranty Shipment Damage Connecting Gas Supply Line Appliance Operation Gas Leakage (If you detect or smell gas...) Maintenance Freeze Protection Fluids and Treatments Product Identification Label Factory Test and Inspections Disclaimers and Local Codes III. Product Rating, Specifications, and Dimensional Data IV. BFIT Component Identification V. Unpacking The BFIT Unpacking and Inspection Installation and Operation Manual VI. Pre-Installation and Mounting General Installation Appliance Mounting Clearances...
  • Page 3 Table of Contents Temperature Rise and Heat Exchanger Head Loss Standard Piping Components Water Quality and Treatments Oxygen Contamination X. Heating Boiler Piping diagrams XI. Hot Water Supply Boiler Water Piping General Piping Guidelines Factory Supplied Outlet Manifold (BFITW) Standard Piping Components Scalding Water Quality Temperature Rise and Heat Exchanger Head Loss Pump Selection XII. Gas Piping Guidelines and Requirements XIII. Electrical General Power Requirements Appliance Wiring XIV. System Start-up Check System Setup Start the BFIT Combustion Air/Fuel Adjustment Field Conversion of Gas Type...

  • Page 4: Hazard Definitions

    I. Hazard Definitions The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. It is critical all personnel read and adhere to all information contained in DANGER, WARNING, and CAUTIONS. All DANGERS, WARNINGS, and CAUTIONS are for reference and guidance purpose, and, therefore, do not substitute for strict adherence to applicable jurisdictional and professional codes and regulations.  DANGER DANGER  CAUTION CAUTION   Indicates an imminent hazardous situation which, if not Indicates a potentially hazardous situation which, if avoided, will result in death, serious injury or substantial not avoided, may result in moderate or minor injury, or property damage. property damage.  WARNING WARNING NOTICE NOTICE  Indicates a potentially hazardous situation which, if not Indicates special instructions on installation, operation, avoided, could result in death, serious injury, or substan- or maintenance which are important but not related to tial property damage.

  • Page 5: Read Before Proceeding

    II. Read Before Proceeding A. Local Codes 2. Do not block or restrict in any way the flow of combustion or ventilation air from or to the 1. This unit shall be installed in accordance with those appliance installation regulations enforced in the area where 3. Do not use this appliance if any part has been under the installation is to be made. These regulations water. Any appliance that has been under water shall be carefully followed in all cases. Authorities must be replaced.

  • Page 6: Factory Test And Inspections

    II. Read Before Proceeding (continued) J. Factory Test and Inspections  WARNING WARNING  1. Prior to shipment, final air-fuel adjustments are performed by factory trained service personnel This product can expose you to chemicals, includ- on each appliance. The factory emissions report ing chromium, which are known to the state of is posted on the back of the front jacket panel as California to cause cancer and birth defects or a reference for troubleshooting and maintenance.

  • Page 7: Product Rating, Specifications, And Dimensional Data

    III. Product Rating, Specifications, and Dimensional Data hot water space heating systems or systems containing BFIT boilers are condensing, high-efficiency, gas-fired, hot significant amount of dissolved oxygen (swimming pool water boilers designed for space heating systems or indirect water heating, direct domestic water heating, etc.). domestic water heating, where supply water temperature does not exceed 190°F. These boilers have special coil type This manual also covers the BFIT Hot Water Supply Boilers stainless steel heat exchangers, constructed, tested, and designed for heating potable water. (BFITW 2500, 3000, stamped per Section IV of the ASME Boiler and Pressure 3500, 4000) Information specific to the Dual Gas model Vessel Code, which provide maximum heat transfer can be found in the appendices.
  • Page 8 III. Product Rating, Specifications, and Dimensional Data (continued) Table 3: Product Dimensions BFIT Model Dimensions (in.) 1000 1250 1500 2000 2500 3000 3500 4000 45-1/2 45-1/2 66-1/8 66-1/8 75-5/8 75-5/8 97-1/8 97-1/8 72-1/2 74-5/8 83-3/4 83-3/4 105-1/8 105-1/8 55-7/8 55-7/8 76-1/2 76-1/2 86-1/2 86-1/2...
  • Page 9 III. Product Rating, Specifications, and Dimensional Data (continued) SUPPLY NOZZLE RETURN NOZZLE GAS TRAIN CONNECTION SUPPLY NOZZLE LIFTING LUGS RETURN NOZZLE (Z-COG) (Y-COG) DRAIN VENT AIR SUPPLY (Z-COG) (X-COG) 1" CONDENSATE DRAIN Figure 1: BFIT Boiler Dimensions...

  • Page 10: Bfit Component Identification

    IV. BFIT Component Identification Communication Interface (Concert Boiler Control) 15. Gas supply line The BFIT series is equipped with the Concert Boiler Provides a means of connection for incoming gas line to Control display which provides easy access for viewing and the gas train assembly. See Table 35 for model specific adjusting operational parameters and alarms/lockouts, and pipe sizes. monitoring historical performance characteristics. 16. Inlet/Return water connection Main appliance control Inlet connection that returns water from the system to the It receives and processes input signals from safety switches...
  • Page 11 IV. BFIT Component Identification (continued) Figure 2: Component Identification...
  • Page 12 IV. BFIT Component Identification (continued) Figure 3: Component Identification...

  • Page 13: Unpacking The Bfit

    V. Unpacking The BFIT A. Unpacking and Inspection 1. Move appliance to approximate installation  WARNING WARNING  location. Failure to assure the truck forks are long enough 2. Remove all crate fasteners. to extend at least half way through the base will 3. Lift and remove outside container. result in the appliance tipping off the lift truck and potentially falling. This will result in severe person- 4. Account for all loose shipped items. al injury, death, or substantial property damage. 5. Remove cardboard positioning sleeves on shipping Do not operate this appliance if any part has been skid. underwater. The possible damage to a flooded 6.

  • Page 14: Pre-Installation And Mounting

    VI. Pre-Installation and Mounting A. General Installation 1. Installation must conform to the requirements of  WARNING WARNING  the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Apply supplied dielectric grease to the gasket Code, ANSI Z223.1/NFPA 54, and/or Natural Gas inside the vent connector. Failure to apply the and Propane Installation Code, CAN/CSA B149.1.

  • Page 15: Appliance Mounting

    VI. Pre-Installation and Mounting (continued) B. Appliance Mounting 1. The BFIT is intended for installation in an area with Table 4: Corrosive Combustion Air Contaminants a floor drain, or in a suitable drain pan to prevent Contaminants to Avoid: any leaks or safety relief valve discharge resulting in property damage. Spray cans containing chlorofluorocarbons (CFC’s) 2. This appliance is not intended to support external piping or venting. All external piping and venting Permanent wave solutions must be supported independently of the appliance. Chlorinated waxes/cleaners 3. This appliance must be installed on a level surface Chlorine-based swimming pool chemicals to prevent condensate from backing up inside the Calcium chloride used for thawing heat exchanger.

  • Page 16: Clearances

    VI. Pre-Installation and Mounting (continued) C. Clearances NOTICE NOTICE 1. The BFIT is approved for 0" clearance to combustible This appliance is approved for zero inch clearance materials. The clearances for serviceability are to combustible or noncombustible material, but found in Table 5. installing the appliance with smaller than the 2. Minimum clearances from combustible or clearances for serviceability will limit access for noncombustible construction, 0" sides, 0" back, maintenance.

  • Page 17: Venting

    VII. Venting A. General Venting Guidelines  WARNING WARNING  1. Install vent system in accordance with National This appliance must not be installed in a room Fuel Gas Code, ANSI Z223.1/NFPA 54 or Natural under negative pressure. These direct vent gas Gas and Propane Installation Code, CAN/CSA fired appliances are allowed a maximum leakage B149.1 Installation Code for Canada, or, applicable...

  • Page 18: Field Installation

    VII. Venting (continued) C. Field Installation 1. A factory installed cast aluminum or steel ring  WARNING WARNING  provides a means for air intake connection. 2. A factory installed vent connector provides a means Failure to follow these instructions could cause for connection to stainless steel venting. products of combustion to enter the building, resulting in severe property damage, personal 3.
  • Page 19 VII. Venting (continued) Table 7: Equivalent lengths of Vent and Combustion Air Components Diameter 6 in. (160 mm) 8 in. (200 mm) 10 in. (250 mm) 12 in. (315 mm) 90° Elbow 7 ft. (2.1 m) 11 ft. (3.4 m) 14 ft. (4.3 m) 18 ft.
  • Page 20 VII. Venting (continued) Table 11: Stainless Steel and CPVC Vent Adapters Stainless Steel to CPVC Heat Fab to Z-Vent Vent Diameter (in.) Bryan Steam Part # Z-Flex Part # 109510-01 2SVSHF08 109510-02 2SVSHF10 109510-03 2SVSHF12 Table 12: Polypropylene Vent Adapters BFIT Vent Centrotherm Part # Z-Flex Part # Model...

  • Page 21: General Termination

    VII. Venting (continued) D. General Termination b. When installed on the same wall, locate vent terminal 4 vent pipe diameters above 1. Use only listed vent/combustion air terminals. the combustion air terminal. The snorkle 2. Follow the termination configurations shown configuration can be used when penetrations are in Table 15, and see Table 18 for acceptable at the same hieght.
  • Page 22 VII. Venting (continued) 13. Maintain minimum 24 in. (610 mm) horizontal 7. If window and/or air inlet is within 4 ft. (1.2 m) spacing between vent terminal and a building of an inside corner, maintain at least 6 ft. (1.8 m) corner. spacing between terminal and adjoining wall of inside corner. 14.
  • Page 23 VII. Venting (continued) Table 16: Direct Vent Terminal Clearances Canadian Installations US Installations Clearance above grade, veranda, 18 in. (46 cm) 12 in (30 cm) porch, deck, or balcony 6 in (15 cm) for appliances ≤ 6 in (15 cm) for appliances 10,000 Btuh (3 kW), 12 in (30 ≤...
  • Page 24 VII. Venting (continued) Table 17: Other than Direct Vent Terminal Clearances Canadian Installations US Installations Clearance above grade, veranda, 18 in (46 cm) 12 in (30 cm) porch, deck, or balcony 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 12 in (30 4 ft (1.2 m) below or to side of Clearance to window or door that cm) for appliances >...
  • Page 25 VII. Venting (continued) Table 18: Table of Acceptable Terminations Flue Gas Vent Terminations Sidewall Roof Straight Termination Tee Termination Vertical Run Tee Termination Vertical Run 20°-45° Elbow Terminated Downward Velocity Cone Combustion Air Intake Terminations Sidewall Roof Two 90° Elbows Terminated Downward 90°...

  • Page 26: Vent And Combustion Air Terminations

    VII. Venting (continued) NOTICE NOTICE Methods of securing and sealing terminals to E. Vent and Combustion Air Terminations the outside wall must not restrain the thermal 1. Vent Piping expansion of the vent pipe. a. Install fire stops where vent passes through floors, ceilings or framed walls. The fire stop Exterior run should be included in equivalent must close the opening between the vent pipe...
  • Page 27 VII. Venting (continued) 6 Pipe Diameters Min. 24 in. Min. Bird Screen From Intake Vent & Intake Bird Screen Vent Vent & Intake 12 in. Min. Above Snow Line 4 Pipe Diameters min. Vent Combustion Combustion Grade/Snow Line 12 in. min. Above Snow Line Figure 6: Horizontal Sidewall Termination Figure 7: Slopped Roof Termination...

  • Page 28: Multiple Appliance Terminations

    VII. Venting (continued) F. Multiple Appliance Terminations 1. Vent Piping Terminations NOTICE NOTICE The joint between the terminal and the last piece of pipe must be outside of the building. a. Multiple appliance vent terminations are shown in Figure 9. b. Each individual appliance must have its own vent pipe and vent terminal unless a common venting system is used following the guidlines of the "Engineered Venting Method" section in...
  • Page 29 VII. Venting (continued) 6D Min. NOTICE NOTICE The required spacing between vent and combustion air terminals is to prevent flue gas recirculation. Recirculation of flue gas products 4D Min. into the combustion air supply can cause damage to property or the appliance. Grade/ Snow Line 12 in.

  • Page 30: Polypropylene Venting

    VII. Venting (continued) H. Polypropylene Venting  WARNING WARNING  1. Running Flexible Polypropylene Vent (Liner) Asphyxiation Hazard. Vent systems made by listed Through Unused Chimney Chase PP vent system manufacturers rely on gaskets for a. It is the responsibility of the installing contractor proper sealing. When this type of vent system is to procure polypropylene vent system pipe and used, take the following precautions: related components. Make sure that gasket is in position and undamaged b. A l l l i s t e d p o l y p ro p y l e n e v e n t sy s t e m in the female end of the pipe.
  • Page 31 VII. Venting (continued) NOTICE NOTICE Pressure drop for flexible polypropylene line is 20 % greater than from rigid pipe. Multiply measured flexible polypropylene liner length by 1.2 to obtain equivalent length. Maximum equivalent vent length of flexible poly- propylene liner is 48 ft. (14.6 m). Installation of a polypropylene vent system should adhere to the vent manufacturer's installation in- structions supplied with the vent system.  WARNING WARNING  DO NOT mix vent systems of differ- ent types or manufacturers. Failure to comply could result in severe per- sonal injury, death, or substantial property damage. Do NOT connect venting to a chim- ney flue that is servicing a separate appliance designed to burn solid fuel.
  • Page 32 VII. Venting (continued) a. Ventilation Air: an opening for ventilation air at c. No manually operated dampers or manually the highest point that opens to the outdoors operated adjustable louvers are permitted. shall provide Ventilation of the space. The cross d. Motorized dampers or Louvers shall be interlocked sectional area of this opening shall be at least so the burner(s) cannot operate unless the 10% of the area required for combustion air, but damper or louver is in the fully open position.

  • Page 33: Removing Existing Appliance

    VII. Venting (continued) J. Removing Existing Appliance When an existing appliance is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances. At the time of removal of an existing appliance, the following steps should be performed with each appliance remaining connected to the common venting system. Make sure the appliances are not in operation while carrying out these steps. 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and ensure there is no blockage or restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. 3. Insofar as is practical, close all exterior doors and windows, and all doors between the space where the appliances connect to the common venting system and other spaces of the building. Turn on any exhaust fans, such as range-hoods and...

  • Page 34: Special Installation Requirements For Massachusetts

    VII. Venting (continued) K. Special Installation Requirements for Massachusetts 1. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: a. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. b. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the detector on the floor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment, the installer shall have a period of thirty (30) days to comply...

  • Page 35: Condensate Disposal

    VIII. Condensate Disposal A. General B. Condensate trap installation 1. Note the following when disposing of the 1. Locate the condensate trap assembly shipped loose condensate: with this appliance. a. Condensate is slightly acidic, typical pH around 2. Install the condensate trap on the lower rear of the 3.5 - 4.5. Do not route the drain line through areas appliance as shown in Figure 11.

  • Page 36: Condensate Neutralizer Installation

    VIII. Condensate disposal (continued) C. Condensate Neutralizer Installation  WARNING WARNING  1. Some jurisdictions may require that the condensate be neutralized before being disposed of. Follow Failure to install the condensate drain in accor- local codes pertaining to condensate disposal. dance with the above instructions could cause 2. A condensate neutralizer kit is available from flue gas to enter the building, resulting in personal factory as optional equipment. Refer to Table 20 for...

  • Page 37: Hydronic Piping

    IX. Hydronic Piping A. BFIT Boiler Piping  CAUTION CAUTION  BFIT boilers are designed to operate in a closed loop pressurized system. Minimum pressure in the boiler Failure to properly pipe boiler may result in im- must be 14.5 psi (100 kpa). Proper operation requires proper operation and damage to the boiler or a piping system that can provide sufficient water structure. flow through the boiler and meet the water quality Install boiler so that the gas ignition system requirements.

  • Page 38: Temperature Rise And Heat Exchanger Head Loss

    XI. Water Piping (continued) D. Temperature Rise and Heat Exchanger Head Loss 1. The BFIT heat exchanger adds pressure drop to the system which must be accounted for in the design of the piping configuration and pump selection. 2. For systems with glycol mixture, the flow rate specified in Table 21 will increase as specified in Table 25 due to the extra frictional loss introduced by the glycol. Size pump accordingly. 3. Strictly follow glycol manufacturer’s guidelines and recommendations when adding glycol in the heating system. 4. The system should be designed to maintain the recommended water flow rate shown in Table 21 while never exceeding the range of absolute flow rates shown in Table 24. Exceeding the maximum water flow rates can cause pipe erosion, damage the flow switch, and allow unsafe operation. a. Maintaining sufficient flow through the boiler will help prevent the buildup of scale. Table 21: Temperature rise, flow rate, and head loss Recommended Range Delta 20 °F Delta 25 °F Delta 30 °F Delta 35 °F...

  • Page 39: Standard Piping Components

    IX. Hydronic Piping (continued) E. Standard Piping Components  WARNING WARNING  1. Safety Relief Valve (Required) Burn Hazard. Safety relief valve discharge shall The BFIT Boiler is shipped with an installed pressure be piped in such a way to prevent or eliminate relief valve. potential burn risk. a. The safety relief valve must be installed with DO NOT pipe in any area where freezing could spindle in vertical position. Installation of the occur.

  • Page 40: Water Quality And Treatments

    IX. Hydronic Piping (continued) 10. Flow Control Valve (Strongly Recommended) The flow control valve prevents flow through NOTICE NOTICE the system unless the circulator is operating. Flow control valves are used to prevent gravity The BFIT heat exchanger is made from stainless circulation in circulator zone systems through zones steel tubular double coil having relatively nar- that are not calling for heat.

  • Page 41: Oxygen Contamination

    IX. Hydronic Piping (continued) b. The TDS (in ppm) is determined by measuring the NOTICE NOTICE electrical conductivity (µS/cm) of the water and multiplying by a conversion factor (typically 0.65 Water temperatures over 140 °F (60 °C) greatly for drinking water). increase the affects of corrosive chemicals. 6. Chlorine and Chloride can be very corrosive to Chlorine and Chloride have different levels of cor- stainless steel. Ensure the level of chlorine is less rosion effects on stainless steel. It is recommended than 5 ppm and the level of chloride is less than for chlorine (Cl2) levels to be below 5ppm and 1000 ppm.
  • Page 42 IX. Hydronic Piping (continued) Table 22: Corrosion/Scale Inhibitors and Removal Agents Producers Fernox Sentinel Sotin ADEY Inhibitors Protector F1/Alphi 11 X100, X500 Sotin 212 MC1+ Noise reducer X200 Universal Restorer X300 Cleaner Sludge remover Protector F1, Cleaner F3 X400 Sotin 212 Antifreeze Alphi 11 X500...

  • Page 43: Heating Boiler Piping Diagrams

    X. Heating Boiler Piping diagrams Figure 14: Single Boiler, Primary/Secondary Piping Single AMP/BFIT Primary/Secondary Piping System Circulator To System Pressure Reducing Valve Isolation Valve Air Vent Purge Valve Make Up Water From System Factory Supplied Manifold Isolation Valve Expansion Tank Check Valve Boiler Circulator Y-Strainer No more than 12 inches or 4 pipe diameters...
  • Page 44 X. Heating Boiler Piping Diagrams (continued) Figure 15: Multiple Boiler, Primary/Secondary with Common Header Piping AMP Pipng with Common Header System Circulator To System Air Vent Make Up Water Purge Valve From System Check Valve Pressure Reducing Valve Expansion Tank Isolation Valve Check Valve Factory Supplied Manifold Y-Strainer...
  • Page 45 X. Heating Boiler Piping Diagrams (continued) Figure 16: Multiple Boiler, Primary Reverse-Return Piping Air Vent From System System Pump Full Port Isolation Valve Expansion Tank Y-Strainer Motorized isolation Valve Pressure Reducing Valve Make Up Water Factory Supplied Manifold Check Valve To System AMP Variable Primary Piping 8/30/2019 1.
  • Page 46 X. Heating Boiler Piping Diagrams (continued) Multiple AMP Boiler Piping with Hydraulic Separator 11/12/2018 Figure 18: Multiple Boiler, Primary Secondary Piping with Hydronic Separator System Circulator Hydraulic Separator Isolation Valve To System Check Valve From System Make Up Water Check Valve Pressure Reducing Valve Expansion Tank Boiler Circulator...

  • Page 47: Hot Water Supply Boiler Water Piping

    XI. Hot Water Supply Boiler Water Piping This Section of the Manual covers the BFIT Hot Water Sup- ply Boiler used for applications other than space heating NOTICE NOTICE where potable water is being heated directly. The BFIT Hot Water Supply Boiler (Models BFITW 2500 - Failure to properly pipe appliance may result in BFITW 4000) is designed for heating potable water. This improper operation and damage.

  • Page 48: Scalding

    XI. Hot Water Supply Boiler Piping (continued) b. The safety relief valve must be installed with the  WARNING WARNING  spindle in a vertical position. Installation of the relief valve must comply with ASME Boiler and Safety Relief Valve Pressure Vessel Code, Section IV. Burn Hazard. Safety relief valve discharge shall c. If the safety relief valve is to be replaced, the be piped in such a way to prevent or eliminate replacement valve must have a relief capacity potential burn risk.

  • Page 49: Water Quality

    XI. Hot Water Supply Boiler Piping (continued)  DANGER DANGER  a. Mixing valves can be installed at the outlet of storage tank or at other zones or fixtures in the system. 2. When appliances such as dishwashers or clothes washers are used in a domestic hot water system that require increased temperatures, two hot water supply's can be set up as shown in Figure 22. 3.

  • Page 50: Temperature Rise And Heat Exchanger Head Loss

    XI. Hot Water Supply Boiler Piping (continued) NOTICE NOTICE Table 28: Water Quality Requirements The BFIT heat exchanger is made from stainless Quality Parameter Minimum Maximum steel tubular double coil having relatively nar- row waterways. Once filled with water, it will be Water Hardness (ppm) subject to the effects of corrosion. Failure to take Total Dissolved Solids (ppm) the following precautions to minimize corrosion, Chlorine (ppm) and overheating could result in severe product damage.

  • Page 51: Pump Selection

    XI. Hot Water Supply Boiler Piping (continued) G. Pump Selection A Circulation pump is a required component for complete installation of this appliance. Choosing the appropriate pump is critical for the functionality, safe operation, and longevity of the appliance. Pumps should be sized for each particular installation based on the required flow rate, water hardness, and total pressure drop in the primary loop between the tank and the boiler. 1. Sizing a sufficient pump will ensure the desired temperature rise and meet the minimum flow rate requirements. Lower flow rates will allow build up of scale and cause more stress on the heat exchanger. a. If the flow rate is too high and the temperature rise is too low, the flow rate can be decreased by adding a restriction in the loop. Install a ball valve or globe valve (recommended) in the outlet side of the primary piping. ii. With the boiler at its maximum input rate (high fire), slowly adjust the globe valve until the temperature rise is within the recommended range shown in Table 29. iii. Water velocities too high may cause erosion within the tubes of the heat exchanger or the primary piping. Failure to adjust the flow rate to the specified values or use the appropriate pipe size can cause non- warrantable damage.
  • Page 52 XI. Hot Water Supply Boiler Piping (continued) Figure 21: Single Appliance, Single Tank Water Heater Piping with Tank Recirculation Filter Cold Water Supply System Circulator Hot Water Return Exansion Tank Check Valve Mixing Valve Factory Supplied Manifold Hot Water Supply Thermometer T&P Relief Valve Storage Tank Water Heater Circulator...
  • Page 53 XI. Hot Water Supply Boiler Piping (continued) P/BFIT 1 Heater 1 Tank 2 Temperature Piping 5/28/2 Figure 22: Two Temperatures, Single Appliance, Single Tank Check Valve Recirculation Filter High Temp Water Supply Thermometer Isolation Vavle Mixing Valve High Temperature Return Low Temp Water Supply T&P Relief Valve Factory Supplied...
  • Page 54 XI. Hot Water Supply Boiler Piping (continued) Figure 23: Single Appliance, Two Tanks FIT Water Heater with 2 Tanks 5/28/20 Recirculation Filter Cold Water Supply System Circulator Expansion Tank Hot Water Return Check Valve Mixing Valve Isolation Valve Hot Water Supply Factory Supplied Manifold Thermometer Storage Tank...
  • Page 55 XI. Hot Water Supply Boiler Piping (continued) wo AMP/BFIT Water Heaters with One Tank Figure 24: Two Appliances, Single Tank System Recirculation Filter Circulator Cold Water Supply Hot Water Return Expansion Tank Check Valve Isolation Valve Mixing Valve Factory Supplied Manifold Hot Water Supply Thermometer Storage Tank...
  • Page 56 XI. Hot Water Supply Boiler Piping (continued) AMP Water Heaters with Two Tanks Figure 25: Two Appliances, Two Tanks Cold Water Supply System Circulator Recirculation Filter Check Valve Expansion Tank Hot Water Return Mixing Valve Hot Water Supply Factory Supplied Manifold Thermometer Water Heater Circulator...

  • Page 57: Gas Piping

    XII. Gas Piping A. Guidelines and Requirements 10. If the high or low gas pressure switch tripped, it All installation must conform to the National Fuel Gas must be manually reset before the appliance can Code ANSI Z223.1/NFPA54, and/or local codes. In Can- be restarted. (See Figure 27) ada, installation must conform to the latest edition of 11. Gas piping shall be supported by fixed hangers or CSA B149.1 National Gas and Propane Gas Installation stands and not by the appliance. Code, and/or local codes. 12. Purge all air from gas lines.
  • Page 58 XII. Gas Piping (continued) Maximum capacity of schedule 40 black pipe in CFH* Table 32:  Natural Gas, Inlet Pressure 14.0 in wc (3.4 kPa)or less; 0.5 in wc (0.12 kPa) Pressure Drop Nominal Inside Length of Pipe (Ft) Pipe Size Diameter (In) (In)
  • Page 59 XII. Gas Piping (continued)  WARNING WARNING Table 34: Specific Gravity Correction Factors  Specific Correction Specific Correction Failure to properly pipe gas supply to appliance may Gravity Factor Gravity Factor result in improper operation and damage. Always assure gas piping is absolutely leak free and of the 0.60 1.00 0.90 0.82 proper size and type for the connected load. 0.65 0.96 0.78 An additional gas pressure regulator may be need- 0.70 0.93...

  • Page 60: Electrical

    XIII. Electrical A. General  DANGER DANGER  Install wiring and electrically ground the appliance in accordance with authority having jurisdiction or, in the Electrical Shock Hazard: Ensure all electrical absence of such requirements, follow the National connections are disconnected before attempting Electrical Code, NFPA 70, and/or Canadian Electrical installation or service of electrical components or Code Part 1, CSA C22.1. connections of the appliance or building. Lockout 1. A separate electrical circuit must be run from all electrical boxes with padlock once power is the main electrical service with an over-current turned off.

  • Page 61: Appliance Wiring

    XIII. Electrical (continued) C. Appliance Wiring c. Avoid placing senors near potential sources of electrical noise such as transformers, power lines, 1. Connect to field wiring inside the control box. . and fluorescent lighting. Wire the sensor to the I I nside the control box are five printed circuit boards appliance using 22 gauge or larger wire. As with (PCB’s). the sensor, the sensor wiring should be routed away from sources of electrical noise. Where it is Table 37: BFIT PCB's impossible to avoid such noise sources, wire the sensor using a 2 conductor, UL Type CM, AWM...
  • Page 62 XIII. Electrical (continued) Boiler must be grounded in accordance with ANSI National Electric Code. Connect to V/C/P Primary Power Supply To Grounding Fuses Ground Screw Conductor Blower Terminal Combustion Blower Power Fuses Fuses used for only 208 V and 230 V Transformer used for only 208 V and 230 V...
  • Page 63 XIII. Electrical (continued) Boiler must be grounded in accordance Connect to V/C/P with ANSI National Electric Code. Power Supply Primary To Grounding Fuses Ground Screw Conductor Blower Terminal Fuses Combustion Blower Power Transformer 120vac 24vac Continue to low Concert Boiler voltage circuit PCB-01 Control (A1167)
  • Page 64 XIII. Electrical (continued) PCB-01 (3A Slow Blow) PCB-05 Continue from high voltage circuit P4b-1 P18a-4 Central Heat P5-11 Concert Boiler 24vac Enable/ Control (A1167) J17/W1 Disable Input (STAT) J8-3 P5-8 P4b-2 P18a-3 J8-6 P5-2 P4b-4 P18a-2 Setpoint or Modulation J8-7 P5-1 P4b-3 P18a-1...
  • Page 65 XIII. Electrical (continued) Concert Boiler Control (A1167) PCB-02 F2 (6.3A Slow Blow) J4-6 P31-4 Power Supply (120 or 24 VAC) P31-5 J4-7 System Pump (Supplied by others) Spare F3 (6.3A Slow Blow) J4-4 P31-2 Power Supply (120 or 24 VAC) P31-6 J4-5 Boiler Pump/Circulator...

  • Page 66: System Start-Up

    XIV. System Start-up A. Check System Setup  DANGER DANGER  1. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer Do not use matches, candles, or other open flame to installation instructions contained in this manual. ignition sources to check for leaks. 2. Confirm all electrical, water, and gas supplies are Make sure that the area around the appliance is turned off at the source and that venting is clear clear and free from combustible materials, gasoline of obstructions. and other flammable vapors and liquids. 3. Flush the system to remove sediment, flux, and other contaminants. This must be done with the appliance isolated from the system.
  • Page 67 XIV. System Start-up(continued) FOR YOUR SAFETY READ BEFORE OPERATING/P OUR VOTRE     SECURITE LISEZ AVANT DE METTRE EN MARCHE WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. AVERTISSEMENT: Quiconque ne respecte pas à...

  • Page 68: Combustion Air/Fuel Adjustment

    XIV. System Start-up(continued) C. Combustion Air/Fuel Adjustment 6. Verify O (or CO ) and CO concentration are within limits specified in Table 38. Note: the values in 1. For high fire adjustment this table are for sea level only. For high altitude a. Lock the appliance in high fire and allow fan speed installation, above 2000 ft. consult factory. and combustion analyzer reading to stabilize before taking combustion readings. To lock in high fire, select MAIN MENU >> OPERATION.

  • Page 69: Field Conversion Of Gas Type

    XIV. System Start-up(continued) D. Field Conversion of Gas Type  WARNING WARNING  This appliance is factory tested and set up for the gas type selected but can be field converted with the Make sure that all adjustments at high fire are following steps. made with the throttle, not offset screw. 1. Connect the new gas supply to the appliance, check The offset screw has been factory set using pre- for leaks, and purge the gas line in accordance with cision instruments and must never be adjusted in the National Fuel Gas Code, ANSI Z223.1/NFPA the field unnecessarily.

  • Page 70: Pump Control

    XIV. System Start-up(continued) E. Pump Control H. Testing of Controls and Safety Devices Ensure the appropriate pump parameters are Prior to placing the appliance in operation, the selected in the Pumps menu of the Concert control. installing contractor or other responsible personnel Refer to the Concert Boiler Control manual for more must perform safety and control device limit tests information.

  • Page 71: Service And Maintenance

    XV. Service and Maintenance IMPORTANT PRODUCT SAFETY INFORMATION IMPORTANT PRODUCT SAFETY INFORMATION REFRACTORY CERAMIC FIBER PRODUCT REFRACTORY CERAMIC FIBER PRODUCT WARNING: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperature above 1805 °F, such as during direct flame contact, RCF changes into crystaline silica, a know carcinogen. When disturbed as a result of servicing or repair, these substances became airborne and, if inhaled, may be hazardous to your health. AVOID Breathing Fiber Particulates and Dust Do not remove or replace RCF parts or attempt any service or repair work involving RCF without Precautionary Measures: wearing the following protective gears: 1.

  • Page 72: General Maintenance

    XV. Service and Maintenance A. General Maintenance  WARNING WARNING  1. Keep the area around the appliance free from combustible materials. (Gasoline and other Read and understand the entire manual before flammable vapors and liquids) attempting installation, start-up, operation, or 2. Keep the area around the combustion air inlet service. Installation and service must be performed terminal free from contaminants.
  • Page 73 XV. Service and Maintenance (continued) 2. Igniter Electrode  DANGER DANGER  a. Disconnect power to the unit and remove ignition electrode from the burner door. This appliance uses flammable gas, high voltage electricity, moving parts, and very hot water under b. Visually inspect igniter assembly (ceramic high pressure. Ensure that all gas and electric power insulators, bracket, and graphite gasket) for damage. Replace igniter assembly if the electrodes supplies are off and that the water temperature is...
  • Page 74 XV. Service and Maintenance (continued)  WARNING WARNING  Failure to properly secure the burner/blower/gas valve assembly to the heat exchanger could lead to property damage, personal injury or loss of life. Read, understand and follow all the instructions and warnings contained in ALL of the component instruction manuals. Graphite Gasket Assure that all safety and operating controls and components are operating properly before placing Sight Glass the appliance back in service. Annually inspect all vent gaskets and replace any Mount exhibiting damage or deterioration. Nipple Sight Glass Gaskets NOTICE NOTICE Bushing...

  • Page 75: Restarting After Prolong Shutdown

    XV. Service and Maintenance (continued) 6. Combustion air filter with air box a. Undo the latches on the filter box to lift the lid and access the filter. b. Clean the filter of dust and debris using compress air or water. c. Replace filter if it appears damaged or deteriorated. d. Reinstall filter and lid. 7. Combustion air filter without air box a. Remove air intake pipe to gain access to the filter. Blow compressed air though the filter to remove dust and debris. b. Replace filter if it appears damaged or deteriorated.

  • Page 76: Appendix A: Tables

    APPENDIX A: Tables I. Hazard Definitions Table 35: Inlet Gas Pressures and Pipe Size II. Read Before Proceeding XIII. Electrical III. Product Rating, Specifications, and Dimensional Data 7 Table 36: Electrical Ratings Table 1: Performance Ratings Table 37: BFIT PCB's Table 2: BFIT Specifications XIV. System Start-up Table 3: Product Dimensions Table 38: Combustion O Levels IV. BFIT Component Identification Table 39: Approximate Throttle Screw Position for Gas Types 69 V. Unpacking The BFIT Table 40: Safety Device Test VI. Pre-Installation and Mounting XV. Service and Maintenance Table 4: Corrosive Combustion Air Contaminants Table 5: Clearances for Serviceability VII. Venting...

  • Page 77: Appendix B: Figures

    APPENDIX B: Figures I. Hazard Definitions II. Read Before Proceeding III. Product Rating, Specifications, and Dimensional Data Figure 1: BFIT Boiler Dimensions IV. BFIT Component Identification Figure 2: Component Identification Figure 3: Component Identification V. Unpacking The BFIT Figure 4: Lifting Lugs VI. Pre-Installation and Mounting VII. Venting Figure 5: Vent Terminal Clearances Figure 6: Horizontal Sidewall Termination Figure 8: Flat Roof Vent Terminations Figure 7: Slopped Roof Termination Figure 9: Multiple Appliance Direct Vent Termination Figure 10: Flexible Vent in Masonry Chimney with Separate Combustion Air Intake VIII. Condensate Disposal Figure 11: Condensate Trap Assembly IX. Hydronic Piping Figure 12: Factory Supplied Water Manifold Figure 13: Heat exchanger water pressure loss X. Heating Boiler Piping diagrams Figure 14: Single Boiler, Primary/Secondary Piping Figure 15: Multiple Boiler, Primary/Secondary with Common Header Piping...

  • Page 78: Appendix C: Default Light-Off And Modulation Rates

    APPENDIX C: Default Light-off and Modulation Rates BFIT Model Parameter 1000 1250 1500 2000 2500 3000 3500 4000 Max Power MBTU 1000 1250 1500 2000 2500 3000 3500 4000 CH/DHW Max. Modulation Rate (RPM) 6200 7600 4600 4800 4500 5500 6200 6400 Minimum Modulation Rate (RPM) 1725...

  • Page 79: Appendix D: The Dual Gas Bfit

    APPENDIX D: The Dual Gas BFIT A. Dual Gas BFIT: General D. Gas Selection 1. The dual Gas construction allows for two gases 1. The Dual Gas BFIT features a gas selection (Natural/ (natural gas and propane gas) to be connected to Propane) switch that electrically separates the two the appliance at one time which allows for quick gas valves. changeovers of fuel type. 2. The Natural/Propane switch is a heavy duty hesitation switch that allows for easy and safe B.
  • Page 80 APPENDIX D (continued) Gas Selection Switch Natural Gas Connection LP/Propane Connection High Gas Pressure Switch Low Gas Pressure Switch Gas Valves Low Gas Pressure Switch High Gas Pressure Switch...
  • Page 81 APPENDIX D (continued) Boiler must be grounded in accordance Connect to V/C/P with ANSI National Electric Code. Primary Power Supply Fuses To Grounding Ground Screw Conductor Blower Terminal Combustion Blower Power Fuses Fuses used for only 208 V and 230 V Transformer used for only 208 V and 230 V...
  • Page 82 APPENDIX D (continued) Boiler must be grounded in accordance Connect to V/C/P with ANSI National Electric Code. Power Supply Primary To Grounding Fuses L2 L3 Combustion Blower Power Ground Screw Conductor Blower Terminal Fuses Transformer 120vac 24vac Continue to low Concert Boiler voltage circuit PCB-01...
  • Page 83 LIMITED WARRANTY FOR BFIT COMMERCIAL CONDENSING BOILERS Stainless Steel Heat Exchangers and Parts/Accessories Subject to the terms and conditions set forth below, Bryan Steam, Peru, Indiana hereby extends the following limited warranties to the original owner of a commercial grade water boiler or Bryan Steam supplied parts and/or accessories manufactured and shipped on or after June 1, 2019: One Year Limited Warranty On Commercial Boilers and Parts / Accessories Supplied by Bryan Steam Bryan Steam warrants to the original owner that its commercial grade stainless steel water boilers and parts/accessories comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage...
  • Page 84 Bryan Steam, LLC Peru, IN 46970 Phone: 765-473-6651 Inquiry@bryansteam.com www.bryanboilers.com...

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