Bryan Boilers FREE FLEX, Installation & Operation Manual, Page: 5 / 100

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Bryan Steam, LLC www.bryanboilers.com
Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 sales@bryansteam.com
Table of Tables
I. Introduction 6
Table 1: Water Flow Switch Settings 7
II. Pre-Installation 9
Table 2: Clearances and Serviceability 10
III. Installation 11
Table 3: Typical Condensate Flow Rate 12
IV. Venting 16
Table 4: Vent and Combustion Air Pipe Diameters
and Maximum Lengths 18
Table 5: Vent and Combustion Air Equivalent Length
Calculation Worksheet 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
Materials 21
Table 10: Stainless Steel and CPVC Vent Adapters 21
Table 11: Polypropylene Vent Adapters
22
Table 12: Stainless Steel Vent and Intake
Terminations 22
Table 13: Polypropylene Vent and Intake
Terminations 22
Table 14: Recommended Venting Configurations
and Material Options 23
Table 15: Other than Direct Vent Terminal
Clearances 26
Table 16: Table of Acceptable Terminations 27
V. Requirements 39
Table 17: Electrical Requirements 39
Table 18: Gas Supply Requirements 40
Table 19: Sound Pressure Levels 40
Table 20: Minimum Water Flow Rates for Variable
Primary Pumping 41
Table 21: Maximum Water Flow Rate for Variable
Primary Pumping 41
Table 22: Water Flow Rates for Primary/Secondary
Pumping at 20°F ΔT 41
Table 23: Water Flow Rates for Primary/Secondary
Pumping at 40°F ΔT 41
Table 24: Water Flow Rates for Constant Volume
Primary Pumping 42
Table 25: GPM Increase for Glycol System 42
VI. Before Operation 42
Table 26: Chemical Agents and Effects 44
Table 27: Recommended Feed Water Limits 45
VII. System Start-Up 45
Table 28: Siemens Nominal Low Fire O
2 48
Table 29: Safety Device Tests 51
VIII. Service, Maintenance, and Inspection 52
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 40
Pipe 61
Table 33: Equivalent Lengths Of Standard Pipe
Fittings And Valves 62
Table 34: Specific Gravity Correction Factors 62
Appendix B: Air Switch Adjustment
Free Flex 1500 - 6000 63
Appendix C: Venting Diagrams 64
Appendix D: Combustion Air Diagrams 65
Appendix E: Boiler Piping Diagrams 66
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