Bryan Boilers FF1000 Installation & Operation Manual Download

Page: 7 / 85

Form: 2435

Revision: 9

Free Flex Installation and Operation Manual

Date: 9-1-2017

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970

Web:

www.

bryanboilers

.com

Phone:

765-473-6651

Fax:

765-473-3074

Email:

[email protected]

1.3

Test and Inspections

Upon the completion of boiler installation,

final air-fuel adjustments are to be made by

factory trained service personnel. The

emissions data and the O

levels at minimum

and maximum input rate can be found on the

back side of the front-boiler’s door, which can

be referenced in the future by the boiler

operator(s) when troubleshooting and

servicing the boiler. In addition, the following

tests and inspections are made on each boiler

at the factory to ensure it meets our highest

safety and functionality standards.



ASME hydrostatic test inspection



Electrical components inspection



Operating & efficiency test



Final engineering inspection



Crating inspection

Danger

DO NOT store or use gasoline or other

flammable vapors or liquids in the vicinity

of this or any other appliance.

If you smell gas vapors, DO NOT try to

operate any appliance—DO NOT touch

any electrical switch or use any phone in

the building. Immediately, call the gas

supplier from a remotely located phone.

Follow the gas supplier’s instructions or if

the supplier is unavailable, contact the fire

department.

Summary of Contents for FF1000

Page 1: ...es bryansteam com i FREE FLEX 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 Boiler Model Serial Number Installation Date Type System Heating Contractor Phone Email Address ...

Page 2: ...ate Drain Trap 13 3 2 7 Gas Supply Connection 14 3 2 7 1 Drip Leg 14 3 2 7 2 Gas Piping Leak Test 14 3 2 7 3 Venting of Gas Train Components 14 3 3 Combustion Air Supply System 14 3 3 1 Combustion Air Openings 15 3 3 1 1 Two Permanent Opening Method 15 3 3 1 2 One Permanent Opening Method 15 3 3 1 3 Mechanical Air Supply Systems 15 3 3 2 Louvers Grilles and Screens 16 3 3 2 1 Louvers and Grilles 1...

Page 3: ...T UP 31 4 1 Concert Boiler Control Display Navigation 31 4 2 System Check 31 4 3 Power the Boiler 31 4 4 Power the Circulators 31 4 5 Pressurize the Fuel System 31 4 6 Boiler Commissioning 32 4 7 Finish Commissioning the Boiler 34 4 8 Re Starting After Prolonged Shutdown 34 4 9 Testing of Controls and Safety Devices 35 4 10 Ignition Failure 36 5 Service Maintenance and Inspection 37 5 1 General Ma...

Page 4: ...mbly 72 Appendix I 3 Gas Train and Upper Vestibule Controls 73 Appendix I 4 Jacket 75 Appendix I 5 Outlet Manifold 77 Appendix I 6 Miscellaneous External Components 79 Appendix I 7 Controls 81 Tables Table 1Water Flow Switch Settings 8 Table 2 Clearances and Serviceability 11 Table 3 Typical Condensate Flow Rate 13 Table 4 Combustion Air and Flue Gas Requirements 19 Table 5 Electrical Requirements...

Page 5: ...ents 80 Table 27 Controls 82 Figures Figure 1 FF1000 External Boiler Connections and Components 9 Figure 2 FF1500 3000 External Boiler Connections and Components 9 Figure 3 Clearances and Serviceability 11 Figure 4 FF 1000 Condensate Drain Trap 13 Figure 5 FF1500 3000 Condensate Drain Trap 14 Figure 6 High Fire Adjustment on the Main Gas Valve Regulator 33 Figure 7 Ignition Assembly 39 Figure 8 Pa...

Page 6: ...ce which are important but not related to personal injury hazards 1 2 Disclaimers and Local Codes Installation must conform to the requirements of the authority having jurisdiction In the absence of such requirements installation must conform to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CGA B149 Installation Codes Where required by the authority having jurisdiction the installation...

Page 7: ...s when troubleshooting and servicing the boiler In addition the following tests and inspections are made on each boiler at the factory to ensure it meets our highest safety and functionality standards ASME hydrostatic test inspection Electrical components inspection Operating efficiency test Final engineering inspection Crating inspection Danger DO NOT store or use gasoline or other flammable vapo...

Page 8: ...air flange 7 Flue gas vent outlet The boiler comes with a standard AL 29 4C stainless steel vent connection 8 Boiler water flow switch The boiler water flow switch is adjustable within the parameters listed in Table 1 Settings Mode Of Operation Switch Closed Switch Open Minimum 18 13 Maximum 50 45 Table 1Water Flow Switch Settings 9 Return water connection A 3 diameter Victaulic grooved connection...

Page 9: ...e 9 1 2017 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 9 Figure 1 FF1000 External Boiler Connections and Components Figure 2 FF1500 3000 External Boiler Connections and Components ...

Page 10: ...ents of the authority having jurisdiction In the absence of such requirements installation must conform to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CGA B149 Installation Codes Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 2 2 Boiler Foundation Before ...

Page 11: ... Description 1000 1500 3000 A Clearance Above Top of Boiler 6 6 B Front of Boiler Burner End 24 25 5 8 CH From Chimney or Vent Collector measured horizontally 18 18 Dim Description 1000 1500 3000 CV From Chimney or Vent Collector measured vertically 18 18 D Rear of Boiler opposite burner end 6 6 EL Left Side tube access side on standard construction 16 23 ER Right Side 6 6 Table 2 Clearances and S...

Page 12: ... servicing 3 2 2 Safety Relief Valves Safety relief valve s are shipped loose Connections are provided in the top of the boiler for the safety relief valve s The safety relief valve discharge piping must be the same size as the safety relief valve discharge opening and run to a point of safe discharge No shutoff valves are to be placed between the relief valve and the appliance or in the discharge...

Page 13: ...o another drain Use Table 3 for sizing the pump sump Table 3 Typical Condensate Flow Rate Model Max Condensate Flow gph FF1000 7 FF1500 10 5 FF2000 16 FF2500 21 5 FF3000 27 Consult local authorities regarding disposal of flue gas condensate into public waste water system Some jurisdictions require that condensate be buffered before discharge This buffering is commonly achieved by draining the cond...

Page 14: ...n must be checked for leaks Leaks shall be checked using a soap and water solution All joints up to the main motorized gas valve shall be checked A pressure gauge shall be installed down stream of the main motorized gas valve and up stream of the manual gas shutoff valve in the closed position to ensure the main motorized valves are not leaking by During commissioning the remainder of the gas trai...

Page 15: ...rce is discouraged No dimension for a round or rectangular opening shall be less than 3 3 3 1 1 Two Permanent Opening Method One opening starting within 12 of the top of the boiler room and one starting within 12 of the bottom of the boiler room shall be provided The openings shall be open directly to the outside or ducted directly to the outside When directly open to the outside or ducted to the ...

Page 16: ...illes shall be fixed in the open position 3 3 2 2 Screens Minimum Screen Mesh Size Screens shall not be smaller than 1 4 mesh 3 3 2 3 Motorized Louvers Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignition and during main burner operation Means shall be provided to prevent the main burner from igniting should the louver...

Page 17: ...d constructed in accordance with the National Fuel Gas Code NFPA 54 ANSI Z223 1 and applicable local building codes to develop a positive flow adequate to convey flue or vent gasses to the outdoors 2 If this boiler is being installed in Massachusetts follow the Massachusetts Code Instructions printed later in this section 3 Consult the vent pipe manufacturer s instructions for vent system assembly...

Page 18: ...um four 4 feet horizontally from electric meters gas meters regulators and relief valves This distance may be reduced if equipment is protected from damage due to condensate or vapor by enclosure overhangs etc 16 Use appropriately designed thimbles when passing through combustible walls or roofs 17 Install fire stops where vent passes through floors ceilings or framed walls The fire stop must clos...

Page 19: ...ure so that flue gasses will not expel to the room through a boiler on standby 2 Common venting with other appliances is prohibited 3 Vent systems shall be designed to maintain a negative 0 001 iwc to negative 0 1 iwc draft at all times from the minimum firing rate to the maximum firing rate measured at the outlet of the boiler 4 A mechanical draft fan may be required to maintain the required nega...

Page 20: ... qualified licensed professional for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detectors with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision cannot be ...

Page 21: ...system instructions shall be included with the appliance or equipment installation instructions and ii The special venting systems shall be Product Approved by the Board and the instructions for the system shall include a parts list and detailed installation instructions d A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all ventin...

Page 22: ...orized damper or louvers shall be interlocked so the burner s cannot operate unless the damper or louver is in the fully open position 3 4 3 3 Mechanical Combustion Air Supply When combustion air is supplied by mechanical means an airflow sensing device shall be installed and wired into the safety limit circuit of the primary safety control to shut off the gas in the even a an air supply failure 3...

Page 23: ...by some local jurisdictions Locate the service switch such that the appliance can be shut off without exposing personnel to danger in the event of an emergency See Table 5 for available voltages Table 5 Electrical Requirements FF1000 Voltage FLA CCA MHP MA 120 1 60 6 6 2 6 46 4 FF1500 Voltage FLA CCA MHP MA 208 240 1 60 6 9 2 6 1 1 4 3 FF2000 to FF3000 Voltage FLA CCA MHP MA 208 240 1 60 8 3 2 6 1...

Page 24: ...easured at 4 1 2 above the floor and 3 from the boiler at the front rear and two sides See Table 7 for decibel readings Table 7 Sound Pressure Levels Decibel Levels Model Front Rear Tube Side Right Side FF1000 FF1500 67 60 61 63 Table 7 Sound Pressure Levels Decibel Levels Model Front Rear Tube Side Right Side FF2000 67 60 61 63 FF2500 62 62 66 61 FF3000 62 62 66 61 3 5 4 Pump and Piping Requireme...

Page 25: ... pressure drop data and Appendix F for typical boiler piping arrangements 3 5 4 1 Water Flow Rates Variable Primary Pumping Systems Variable primary pumping systems shall be capable of delivering no less than the minimum and no more than the maximum specified in Table 8 and Table 9 for each boiler connected in the system Model Minimum Flow Rate gpm Δ P ft High Fire Δ T FF1000 19 51 100F FF1500 29 ...

Page 26: ...pm Δ P ft High Fire Δ T Low Fire Δ T FF1000 95 12 7 20F 4F FF1500 143 9 2 20F 4F FF2000 190 16 3 20F 4F FF2500 238 20 20F 4F FF3000 285 28 7 20F 4F Table 10 Water Flow Rates for Primary Secondary Pumping 20F ΔT Model 40 F Δ T Flow Rate gpm Δ P ft High Fire Δ T Low Fire Δ T FF1000 48 3 18 40F 8F FF1500 71 2 3 40F 8F FF2000 95 4 08 40F 8F FF2500 119 5 40F 8F FF3000 143 7 18 40F 8F Table 11 Water Flo...

Page 27: ...ss steels that can be severely damaged when exposed to chlorides The removal of pipe chips and other debris from the system before opening the isolation valves to the boiler and pumps will help to protect this equipment from damage by such debris In combination with system contamination bacteria from ground water boiler water may produce objectionable odors sometimes resembling the odorant used in...

Page 28: ...hould the customer refuse cleaning it is necessary to install filtration equipment Install either a fibrous filter or a centrifugal filter in the boiler return piping This will collect and remove sediment from the system A booster pump may be required to overcome the additional pressure drop introduced in the line by the filter When filling the system provide chemical treatment as outlined in Sect...

Page 29: ...uirements and Associated Steam Quality for Industrial Commercial and Institutional Boilers 3 8 2 Objectives The basic objectives of water treatment are 1 Prevent the accumulation of scale and deposits in the boiler 2 Remove dissolved gases from the water 3 Protect the boiler against corrosion 4 Maintain the highest possible boiler fuel efficiency 5 Decrease the amount of boiler down time from clea...

Page 30: ...oxygen from the water Dissolved oxygen will cause severe system corrosion Dissolved Oxygen 0 007 ppm Total Iron 0 1 ppm Total Copper 0 05 Total Hardness 9 ppm 0 5 grains gal pH 8 3 10 0 Nonvolatile TOC 1 ppm Oily Matter 1 ppm Table 14 Recommended Feed Water Limits CAUTION Bryan Steam Standard Warranty does not cover problems caused by oxygen contamination of boiler water Bryan Steam Standard Warra...

Page 31: ...e parameter The user can access the following icons from the Home screen Menu Info Status Adjust and Help It is important that the user become familiar in accessing additional icons that are not shown on the home screen page NOTICE Refer to the Concert Boiler Control manual for detailed instructions on the use of the hydronic control and display 4 2 System Check 1 Verify that the venting water pip...

Page 32: ...flue gas outlet 4 Verify the high temperature limit auto reset is set to 200 0F 1000 only 5 Verify the high and low gas pressure switch limits a High gas pressure switch at 1 0 w c b Low gas pressure switch at 3 0 w c 6 Menu Operation Auto Manual Rate Control Manual 76 password required 7 Switch boiler circuit breaker in the control panel to the ON Position 1000 only 8 Close the manual gas valve b...

Page 33: ... are adjusted with the gas shutter valve located on the outlet of the gas valve i Turn adjustment screw toward the Plus side to increase gas flow decrease O2 level ii Turn adjustment screw toward the Minus side to decease gas flow increase O2 level 24 Menu Operation High Low Low Back Arrow 76 password required 25 Verify the O2 level is within 0 3 of the O2 level set at high fire with all jacket do...

Page 34: ... boiler into automatic mode Menu Operation Auto Manual Rate Control Automatic 76 password required 4 8 Re Starting After Prolonged Shutdown Use the following recommendations prior to re starting the heating system after prolonged shutdown 1 Perform Pre Start Up Inspection by checking all gas water air intake and venting connections to ensure proper leak free connections and that the water and gas ...

Page 35: ...Lockout Gas Pressure Switch Burner Thermal Fuse Disconnect one wire of the burner thermal fuse Cycle the boiler Re connect wiring to the burner thermal fuse Reset burner thermal fuse lockout Hard Lockout Burner Thermal Fuse Blocked Condensate Switch Disconnect one wire of the blocked condensate switch Cycle the boiler Re connect wiring to the blocked condensate switch Reset blocked condensate swit...

Page 36: ...re After the first ignition failure the boiler goes into a hard lockout and a manual reset of the Concert Boiler Control is required to restart the boiler The boiler will then attempt to light off after it has completed its post purge process DANGER Contact the boiler manufacturer or a qualified heating service technician if the boiler has failed to light consecutively three times after initially ...

Page 37: ...vice technicians only If any controls are replaced they must be replaced with identical models supplied by Bryan Steam Read understand and follow all the instructions and warnings contained in all the sections of this manual The instructions and warnings contained in all of the component instruction manuals If any electrical wires are disconnected during service clearly label the wire and ensure t...

Page 38: ...es should be inspected at least once annually Any accumulation of soot or debris should be thoroughly cleaned out 2 If inspection of the boiler tube surfaces reveals a build up of soot carbon the tube surfaces should be thoroughly brushed Failure to do so may result in reduced efficiency fire and asphyxiation hazards 3 The boiler pressure vessel and piping should be checked annually 4 Inspect the ...

Page 39: ...burner to remove lint and debris accumulation Be careful when cleaning the burner assembly to avoid damaging the metal mesh burner surface 3 If the burner or the burner gasket shows any visual deterioration or corrosion signs replace it immediately 4 After replacing the burner or burner gaskets check for proper operation by performing combustion analysis as well as checking for gas leakage around ...

Page 40: ...er equipment as a result of tube failures a Shut off power to the boiler immediately from the external dedicated electrical disconnect b Confirm that any water leakage is not the result of a blocked condensate drain line c Confirm that any water leakage is not the result of a blocked condensate drain line d Remove the boiler s left side jacket panels and flue collector access panels as shown in Fi...

Page 41: ...llation and Operation Manual Date 9 1 2017 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 41 Figure 8 Panel Removal in Preparation for Tube Inspection ...

Page 42: ...of the handle Alternate with downward blows to lift tube end 3 Clear tube end from the header Continue driving wedge under and leveraging flange up until it pops the end of the tube free from the hole in the header 4 Pull upper tube end Repeat the procedure to the pull the tube end of the same tube from the upper header Figure 9 Tube Puller Insertion 5 Prepare the headers and replacement tubes Bef...

Page 43: ...g 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 8 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 end...

Page 44: ...ontrol circuit of the boiler which prevents the boiler from operating Power is interrupted until the control is manually reset pressing the control s reset button When the button is pressed power will again be supplied to the control circuit assuming that the boiler water temperature has dropped below the setpoint minus the differential setting Water Flow Switch If the water flow through the boile...

Page 45: ...properly Boiler is not responding to call for heat Status shows Standby and Priority shows Central Heat or Domestic Hot Water Boiler is not firing or temperature is greater than setpoint Select display Help icon and review Limit String Status Boiler is Running but System or Boiler Circulator is not running Pump Not Running Check wiring for loose connections or wiring errors When there is a Domesti...

Page 46: ...he green light When the faulty wiring reconnected green light will begin to flash Blank Screen with Reading shown Display lost communication with Control Failure to establish Communication upon boot up once you establish communication reboot display to read controller and setup display properly Communication Error 2 Un configured control or control has a memory failure The display write attempt ha...

Page 47: ...46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 Email sales bryansteam com 47 Table 17 General Troubleshooting INDICATION POSSIBLE CAUSE CORRECTIVE ACTION Leakage Remove the boiler s side panels and check for flue gas leakage around the heat exchanger burner mounting plate and blower transition piece ...

Page 48: ...er 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 18 Maximum Gas Capacity Of Schedule 40 Pipe Pipe Length in Equivalent Feet Pipe Size nps ...

Page 49: ... 5 72 2 06 96 4 12 1 1 049 61 29 1 14 6 7 27 2 62 1 22 5 24 1 1 4 1 38 81 38 3 19 1 9 58 3 45 1 61 6 9 1 1 2 1 61 94 44 7 22 4 11 2 4 02 1 88 8 04 2 2 067 1 21 57 4 28 7 14 4 5 17 2 41 10 3 2 1 2 2 469 1 44 68 5 34 36 17 1 6 16 2 88 12 3 3 3 068 1 79 85 2 42 6 21 3 7 67 3 58 15 3 4 4 026 2 35 112 56 28 10 1 4 7 20 2 6 6 065 3 54 168 84 1 42 1 15 2 7 07 30 4 Equivalent lengths are for standard scre...

Page 50: ...rop in Equivalent Feet Flue Vent 8 1 10 5 1728 10 31 3 125 1 56 1106 12 12 1 19 59 768 FF2500 Pressure Drop in Equivalent Feet Flue Vent 8 1 563 16 67 8 33 2158 10 478 5 2 44 1381 12 183 1 852 92 959 FF3000 Pressure Drop in Equivalent Feet Flue Vent 8 2 22 25 11 11 2591 10 68 7 14 3 57 1650 12 267 2 7 1 35 1152 FF1000 Pressure Drop in Equivalent Feet Combustion Air Duct Air Duct Diameter in Straig...

Page 51: ...Flex Installation and Operation Manual Date 9 1 2017 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 51 Appendix C Installation Startup Report ...

Page 52: ... and Operation Manual Date 9 1 2017 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 52 Appendix D Venting Diagrams Appendix D 1 Typical Horizontal Vent Piping ...

Page 53: ...nstallation and Operation Manual Date 9 1 2017 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 53 Appendix D 2 Typical Vertical Pressurized Venting ...

Page 54: ...peration Manual Date 9 1 2017 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 54 Appendix E Combustion Air Diagrams Appendix E 1 Typical Horizontal Air Intake Piping ...

Page 55: ...Installation and Operation Manual Date 9 1 2017 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 55 Appendix E 2 Typical Vertical Air Intake Piping ...

Page 56: ...d Operation Manual Date 9 1 2017 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 56 Appendix F Boiler Piping Diagrams Appendix F 1 Single Boiler Primary Secondary ...

Page 57: ...lation and Operation Manual Date 9 1 2017 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 57 Appendix F 2 Multiple Boilers Primary Reverse Return Piping ...

Page 58: ...n and Operation Manual Date 9 1 2017 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 58 Appendix F 3 Multiple Boilers Primary Secondary Reverse Return Piping ...

Page 59: ...tallation and Operation Manual Date 9 1 2017 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 59 Appendix F 4 Multiple Boilers Primary Secondary Piping ...

Page 60: ...eration Manual Date 9 1 2017 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 60 Appendix F 5 Multiple Boilers Primary Secondary Piping Heating with Domestic Hot Water ...

Page 61: ...on Manual Date 9 1 2017 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 61 Appendix F 6 Multiple Boilers Primary Secondary Piping Heating with Domestic Hot Water continued ...

Page 62: ...36 0 58 80F 48 1 02 70F 27 1 04 70F 41 0 75 70F 54 1 33 60F 32 1 41 60F 48 1 02 60F 63 1 81 50F 38 2 03 50F 57 1 47 50F 76 2 61 45F 42 2 51 45F 63 1 82 45F 84 3 22 40F 48 3 18 40F 71 2 30 40F 95 4 08 35F 54 4 15 35F 81 3 00 35F 109 5 32 30F 63 5 64 30F 95 4 09 30F 127 7 24 25F 76 8 13 25F 114 5 89 25F 152 10 43 20F 95 12 70 20F 143 9 20 20F 190 16 30 FREE FLEX 2500 FREE FLEX 3000 Delta T GPM Ft Hd...

Page 63: ...ation and Operation Manual Date 9 1 2017 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 63 Appendix H Wiring Diagrams Appendix H 1 FF1000 Wiring Diagram ...

Page 64: ...Manual Date 9 1 2017 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 64 Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy ...

Page 65: ...ion and Operation Manual Date 9 1 2017 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 65 Appendix H 2 FF1500 To FF3000 115 VAC Single Phase Wiring Diagram ...

Page 66: ...n and Operation Manual Date 9 1 2017 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 66 Appendix H 3 FF1500 To FF3000 208 230 VAC Single Phase Wiring Diagram ...

Page 67: ...Manual Date 9 1 2017 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 67 Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy ...

Page 68: ...on and Operation Manual Date 9 1 2017 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 68 Appendix H 4 FF2000 To FF3000 208 460 VAC Three Phase Wiring Diagram ...

Page 69: ...Manual Date 9 1 2017 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 69 Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy ...

Page 70: ...com 70 Appendix I Repair Parts All boiler Repair Parts may be obtained through your local authorized Bryan Steam Representative Should you require assistance in locating a Bryan Steam representative in your area or have questions regarding the availability of Bryan Steam products or repair parts please contact Bryan Steam Customer Service at 717 239 7642 or Fax 877 501 5212 Appendix I 1 FF1000 Hea...

Page 71: ...ont Panel 1 1 105538 01 9 Flue Collector Side Panel 1 1 105540 01 10 Flue Collector Center Panel 1 1 105537 01 11 Flue Collector Top Panel 1 1 105541 01 12 Condensate Pan 1 1 105260 01 13 Horz Convection tube Access Door Clamp 2 2 105263 01 14 Horz Furnace Tube Access Door Clamp 2 2 105262 01 15 Vert Tube Access Door Clamp 3 3 105261 01 16 Bottom Reinforcement Plate 1 1 105281 01 17 Vertical Cente...

Page 72: ... Assembly Table 22 Burner Assembly Item Number Description Quantity Part Number 1 Ultra Violet UV Scanner 1 106684 01 2 Heat Insulator 1 8026217 3 Ultra Violet UV Lens Gasket 2 107031 01 4 Ultra Violet UV Scanner Bracket 1 106685 01 5 Igniter Scanner Gasket 1 105246 02 6 Burner 1 105618 01 7 Ultra Violet UV Lens 1 107032 01 8 Igniter 1 105678 01 9 Site Glass Bushing 1 105657 01 10 Site Glass Gaske...

Page 73: ...stallation and Operation Manual Date 9 1 2017 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 73 Appendix I 3 Gas Train and Upper Vestibule Controls ...

Page 74: ...326 01 3B Swirl Plate 1 105327 01 3C Manual Shut Off Ball Valve 1 105325 01 3D Main Gas Valve 1 105330 01 3E High Gas Pressure Switch 1 105328 01 3F Low Gas Pressure Switch 1 105329 01 3G Ball Valve 1 1 8 Tapping 1 105324 01 3H Blower Adapter 1 105259 01 3I 1 4 NPT Plug 2 806603599 3J 1 4 NPTx1 4 Tube Compression Fitting 2 822658 3K Pressure Switch Tubing 3FT 92465560 3L Minimum Air Pressure Switc...

Page 75: ...n 9 Free Flex Installation and Operation Manual Date 9 1 2017 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 75 Appendix I 4 Jacket ...

Page 76: ...cket Key No Description Quantity Part Number 4A Base 1 105124 01 4B Front Left Corner 1 105172 01 4C Front Right Corner 1 105172 04 4D Center Rail 1 105176 01 4E Hinges 2 105714 01 4F Front Lower Panel 1 105177 01 4G Front Door 1 105170 04 4H Front Upper Panel 1 105169 01 4J Top Panel 1 105174 04 4K Rear Panel 1 105173 02 4L Side Door 1 105178 02 4M Air Intake Filter 1 811SOL0020 Not Shown Black S...

Page 77: ...Free Flex Installation and Operation Manual Date 9 1 2017 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 77 Appendix I 5 Outlet Manifold ...

Page 78: ...Panel Water Outlet Manifold 1 105382 01 5C 3 Victaulic Coupling 3 104035 02 5D 1 2 NPT Air Vent 1 102260 01 5E Temperature Pre ssure Gauge 1 103470 01 1 103470 02 1 103470 03 5F Pressure Relief Valve 1 81660 338 1 816603 59 1 816603 75 1 816603 74 1 816603 77 1 816603 73 1 816603 78 5G 3 Cap 1 104035 03 5H LWCO Probe 1 80160592 5I Immersion Well For Auto Reset High Limit 1 105684 01 5J Brass Immer...

Page 79: ... Installation and Operation Manual Date 9 1 2017 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 79 Appendix I 6 Miscellaneous External Components ...

Page 80: ...nsate Trap 1 105432 01 6E 3 Victaulic Coupling 3 104035 02 6F 3 Cap 1 104035 03 6G Water Inlet Outlet Manifold Trim Ring and Gasket 3 105211 02 3 8205644 6H Vent Outlet Trim Ring and Gasket 1 105211 01 1 105486 01 6J J box and J box Cover 1 8136056 1 8136027 6K Water Flow Switch 1 105687 01 6L Brass Immersion Well Inlet Temperature Sensor 10Kohm 1 105684 01 1 105685 01 6M St Steel Immersion Well S...

Page 81: ... 9 Free Flex Installation and Operation Manual Date 9 1 2017 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 81 Appendix I 7 Controls ...

Page 82: ...1 7B Concert Boiler Control 1 105681 01 7C 24VDC Transformer 1 105680 01 7D 120 24V Step down Transformer 1 801600502 7E Low Water Cut Off Reset Box 1 80160591 7F Display 1 105682 01 7G On Off Switch 1 105658 01 7H Ignition Transformer 1 80160208 7J Ignition Cable 1 105218 01 7K Blocked Condensate Switch 1 105659 01 Not Shown Control Limit Power Harness 1 105660 01 Not Shown Communication Sensing ...

Page 83: ...hermal shock This warranty does not cover damages or failures that can be attributed to corrosion scale dirt or sludge accumulation in the boiler low water conditions failure of any safety devices or any other improper service operation or neglect FLUE GAS CORROSION WARRANTY Subject to the terms and conditions herein Seller warrants to the original owner at the original installation site that the ...

Page 84: ... by the owner either mounted or un mounted or when contracted for by the owner to be installed or handled H Leakage or other malfunction caused by 1 Defective installations in general and specifically any installation which is made a In violation of applicable state or local plumbing housing or building codes b Without a certified ASME pressure relief valve or c Contrary to the written instruction...

Page 85: ...73 6651 Fax 765 473 3074 Email sales bryansteam com 85 conform and be limited to one year from the date of shipment Severability To the extent that any provisions shall of this warranty would be void or prohibited under applicable law such provisions shall be limited in effect to the minimum extent necessary to render the remaining provisions hereof enforceable ...

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