Bryan Boilers FREE FLEX FF1500-3000 Manuals

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Bryan Boilers FREE FLEX FF1500-3000 Installation & Operation Manual (68 pages)

Brand: Bryan Boilers | Category: Boiler | Size: 6 MB

Table of Contents
2
Introduction
5
Important Information
5
Disclaimers and Local Codes
5
Test and Inspections
6
Component Description (See Figure 1 to Figure 3)
6
Table 1: Water Flow Switch Settings
6
Figure 1: FF1000 External Boiler Connections
7
Figure 2: FF1500-3000 External Boiler Connections
7
Figure 3: FF3500-6000 External Boiler Connections
7
Pre-Installation
8
Installation Conformance
8
Boiler Foundation
8
Clearance and Serviceability
8
Figure 4: Clearances and Serviceability
9
Table 2: Clearances And Serviceability
9
Installation
10
Receiving the Boiler
10
Boiler Water and Condensate Connections
10
Condensate Trap/Drain Assembly
11
Figure 5: Condensate Drain
11
Figure 6: Condensate Assembly Orientation
11
Table 3: Typical Condensate Flow Rate
11
Gas Supply Connections
12
Combustion Air Supply System
12
Venting
15
General Venting
15
Category II Venting
16
Massachusetts
17
Table 4: Combustion Air And Flue Gas Requirements
17
Venting Requirements for Canada
18
Requirements
20
Electrical
20
Gas Supply Requirements
20
Table 5: Electrical Requirements
20
Table 6: Gas Supply Requirements
20
Sound Pressure Levels
21
Pump and Piping Requirements
21
Table 7: Sound Pressure Levels
21
Table 8: Minimum Water Flow Rates for Variable Primary Pumping
21
Table 9: Maximum Water Flow Rate for Variable Primary Pumping
21
Table 10: Water Flow Rates for Primary/Secondary Pumping at 20°F ΔT
22
Table 11: Water Flow Rates for Primary/Secondary Pumping at 40°F ΔT
22
Table 12: Water Flow Rates for Constant Volume Primary Pumping
22
Table 13: GPM Increase for Glycol System
22
Before Operation
23
Pre-Boil out Flushing of System
23
Boiler out Procedure
23
Replacement Boiler Installations
23
Boiler Water Treatment
24
Draining and Refilling the Boiler & System
24
Table 14: Chemical Agents and Effects
25
Table 15: Recommended Feed Water Limits
25
System Start-Up
26
Concert Boiler Control Display Navigation
26
System Check
26
Power the Boiler
26
Power the Circulators
26
Pressurize the Fuel System
26
Boiler Commissioning
26
Commissioning FF1000 - FF3000
27
Table 16: Siemens Nominal Low Fire O2
28
Finish Commissioning the Boiler (FF1000-FF3000)
29
Commissioning FF3500 - FF6000
29
Re-Starting after Prolonged Shutdown
29
Bryan Steam LLC, 783 N Chili Ave, Peru, in 46970 Web: Www.bryanboilers.com
29
Figure 8: Siemens Valves
29
Figure 7: High Fire Adjustment On Main Gas Valve (FF1000-FF3000)
29
Testing Controls and Safety Devices
30
Ignition Failure
30
Table 17: Safety Device Tests
30
Service, Maintenance, and Inspection
31
General Maintenance
31
Daily
31
Weekly
32
Monthly
32
Annually
32
Ignition Assembly Cleaning
32
Burner Assembly Cleaning
32
Figure 9: Ignition Assembly
32
Heat Exchanger Cleaning
33
Tube Replacement Procedure
33
Figure 10: Panel Removal in Preparation for Tube Inspection - FF1000
34
Figure 11: Panel Removal in Preparation for Tube Inspection - FF1500-FF3000
34
Figure 12: Panel Removal in Preparation for Tube Inspection - FF3000-FF6000
35
Figure 13: Tube Puller Insertion
36
Safety and Operating Controls
37
Troubleshooting
38
Table 18: Safety and Operating Controls
38
Table 19: General Troubleshooting
39
Appendix A: Sizing Gas Piping
40
Table 20: Maximum Gas Capacity of Schedule 40 Pipe
40
Table 21: Equivalent Lengths of Standard Pipe Fittings and Valves
41
Table 22: Specific Gravity Correction Factors
41
Appendix B: Vent and Combustion Air Pressure Drop Data
42
Table 23: Vent Pressure Drop Data
42
Table 24: Combustion Air Pressure Drop Data
43
Appendix C: Installation & Startup Report
44
Appendix D: Venting Diagrams
45
Figure 15: Typical Vertical Pressurized Venting
45
Figure 14: Typical Horizontal Vent Piping
45
Appendix E: Combustion Air Diagrams
46
Figure 16: Typical Horizontal Air Intake Piping
46
Figure 17: Typical Vertical Air Intake Piping
46
Appendix F: Boiler Piping Diagrams
47
Figure 18: Single Boiler, Primary / Secondary
47
Figure 19: Multiple Boilers, Primary Reverse-Return Piping
48
Figure 20: Multiple Boilers, Primary / Secondary Reverse Return Piping
49
Figure 21: Multiple Boilers, Primary / Secondary Piping
50
Figure 22: Multiple Boilers, Primary / Secondary with Indirect Water Heater
51
Appendix G: Water Flow Pressure Drops
52
Appendix H: Wiring Diagrams
54
Figure 23: FF1000 Wiring Diagram
54
Figure 24: FF1500 to FF3000 115 VAC Single Phase Wiring Diagram
56
Figure 25: FF1500 to FF3000 208 - 230 VAC Single Phase Wiring Diagram
58
Figure 26: FF2000 to FF3000 208-460 VAC Three Phase Wiring Diagram
60
Figure 27: FF3500 to FF6000 208-460 VAC Three Phase Wiring Diagram
62

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Bryan Boilers FREE FLEX FF1500-3000 Installation & Operation Manual (68 pages)

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