Bryan Boilers FREE FLEX Manuals

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Bryan Boilers FREE FLEX Installation & Operation Manual (100 pages)

High Efficiency, Low Emission CONDENSING BOILER

Brand: Bryan Boilers | Category: Boiler | Size: 13 MB

Table of Contents
2
Introduction
6
Important Information
6
Disclaimers and Local Codes
6
Test and Inspections
7
Component Description
7
Touchscreen Display
7
Table 1: Water Flow Switch Settings
7
Figure 1: Free Flex 1000 External Boiler Connections
8
Figure 2: Free Flex 1500-3000 External Boiler Connections
8
Figure 3: Free Flex 3500-6000 External Boiler Connections
8
Pre-Installation
9
Installation Conformance
9
Boiler Foundation
9
Clearance and Serviceability
9
Figure 4: Clearances and Serviceability
10
Table 2: Clearances and Serviceability
10
Installation
11
Receiving the Boiler
11
Boiler Water and Condensate Connections
11
Condensate Trap/Drain Assembly
12
Figure 5: Condensate Drain Trap
12
Figure 6: Condensate Assembly Orientation
12
Table 3: Typical Condensate Flow Rate
12
Gas Supply Connections
13
Combustion Air Supply System
13
Venting
16
General Venting Guidelines
16
Venting Design Requirements
17
Field Installation
17
Table 4: Vent and Combustion Air Pipe Diameters
18
Table 5: Vent and Combustion Air Equivalent Length
18
Table 6: Vent Air Pressure Drop Data
19
Table 7: Combustion Air Pressure Drop Data
20
Table 8: Combustion Air and Flue Gas Requirements
21
Table 9: Approved Vent Manufacturers and
21
Table 10: Stainless Steel and CPVC Vent Adapters
21
Table 11: Polypropylene Vent Adapters
22
Table 12: Stainless Steel Vent and Intake
22
Table 13: Polypropylene Vent and Intake
22
Table 14: Recommended Venting Configurations and Material Options
23
General Termination
24
Figure 7: Vent Terminal Clearances
25
Table 15: Other than Direct Vent Terminal
26
Table 16: Table of Acceptable Terminations
27
Vent and Combustion Air Terminations
28
Figure 8: Horizontal Sidewall Termination
29
Figure 9: Slopped Roof Termination
29
Multiple Appliance Terminations
30
Figure 10: Flat Roof Vent Terminations
30
Terminal Installation
31
Figure 11: Multiple Appliance Direct Vent Termination
32
Polypropylene Venting
33
Optional Room Air for Combustion
33
Figure 12: Flexible Vent in Masonry Chimney with Separate Combustion Air Intake
36
Removing Existing Appliance
37
Special Installation Requirements for Massachusetts
37
Requirements
39
Electrical
39
Table 17: Electrical Requirements
39
Gas Supply Requirements
40
Sound Pressure Levels
40
Pump and Piping Requirements
40
Table 18: Gas Supply Requirements
40
Table 19: Sound Pressure Levels
40
Table 20: Minimum Water Flow Rates for Variable
41
Table 21: Maximum Water Flow Rate for Variable
41
Table 22: Water Flow Rates for Primary/Secondary
41
Table 23: Water Flow Rates for Primary/Secondary
41
Before Operation
42
Pre-Boil out Flushing of System
42
Boiler out Procedure
42
Table 24: Water Flow Rates for Constant Volume
42
Table 25: GPM Increase for Glycol System
42
Replacement Boiler Installations
43
Draining and Refilling the Boiler & System
43
Boiler Water Treatment
44
Table 26: Chemical Agents and Effects
44
System Start-Up
45
Concert Boiler Control Display Navigation
45
Table 27: Recommended Feed Water Limits
45
System Check
46
Power the Boiler
46
Power the Circulators
46
Pressurize the Fuel System
46
Boiler Commissioning
46
Commissioning Free Flex 1000 - Free Flex 3000
46
Figure 13: Dungs Valve
48
Figure 14: Siemens Valves
48
Table 28: Siemens Nominal Low Fire
48
Dual Fuel Free Flex 1500 - Free Flex 6000 - Switching Fuels
49
Commissioning Free Flex 1500 - Free Flex 6000 High Turndown or Dual Fuel
49
Flex 6000
50
Re-Starting after Prolonged Shutdown
50
Testing Controls and Safety Devices
51
Ignition Failure
51
Table 29: Safety Device Tests
51
Service, Maintenance, and Inspection
52
General Maintenance
52
Daily
52
Weekly
53
Monthly
53
Annually
53
Ignition Assembly Cleaning
53
Figure 15: Free Flex 1000-3000 Ignition Assembly
53
Burner Assembly Cleaning
54
Heat Exchanger Cleaning
54
Tube Replacement Procedure
54
Figure 16: Free Flex 3500-6000 Ignition Assembly
54
Figure 17: Panel Removal in Preparation for Tube Inspection - Free Flex 1000
55
Figure 18: Panel Removal in Preparation for Tube Inspection - Free Flex 1500 - Free Flex 3000
55
Figure 19: Panel Removal in Preparation for Tube Inspection - Free Flex 3000 - Free Flex 6000
56
Figure 20: Tube Puller Insertion
57
Safety and Operating Controls
58
Troubleshooting
59
Table 30: Safety and Operating Controls
59
Table 31: General Troubleshooting
60
Appendix A: Sizing Gas Piping
61
Table 32: Maximum Gas Capacity of Schedule
61
Table 33: Equivalent Lengths of Standard Pipe
62
Table 34: Specific Gravity Correction Factors
62
Appendix B: Air Switch Adjustment Free Flex 1500 - 6000
63
Appendix C: Venting Diagrams
64
Figure 21: Typical Horizontal Vent Piping
64
Figure 22: Typical Vertical Pressurized Venting
64
Appendix D: Combustion Air Diagrams
65
Figure 23: Typical Horizontal Air Intake Piping
65
Figure 24: Typical Vertical Air Intake Piping
65
Appendix E: Boiler Piping Diagrams
66
Figure 25: Single Boiler, Primary / Secondary
66
Figure 26: Multiple Boilers, Primary Reverse-Return Piping
67
Figure 27: Multiple Boilers, Primary / Secondary Reverse Return Piping
68
Figure 28: Multiple Boilers, Primary / Secondary Piping
69
Figure 29: Multiple Boilers, Primary / Secondary with Indirect Water Heater
70
Appendix F: Water Flow Pressure Drops
71
Appendix G: Wiring Diagrams
72
Appendix H: Thermal Solutions (Seller) Limited Warranty
98
Appendix I: Installation & Startup Report
99

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Bryan Boilers FREE FLEX Installation & Operation Manual (100 pages)

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