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Bryan Boilers FREE FLEX Installation & Operation Manual Download Page 9

9

Bryan Steam, LLC 

                                                                                                                                    www.bryanboilers.com   

Phone: 765-473-6651 

                                        783 N Chili Ave, Peru, IN 46970                                 [email protected]

II. Pre-Installation

The customer should examine the equipment for 

any damage.  It is the responsibility of the installer 

to ensure all parts supplied with the equipment are 

fitted in a correct and safe manner.

WARNING

This boiler requires regular maintenance and service 

to operate safely. Follow the instructions contained 

in this manual.

WARNING

Improper  installation,  adjustment,  alteration, 

service, or maintenance can cause property damage, 

personal injury or loss of life. Read and understand 

the entire manual before attempting installation, 

start-up operation, or service. Only an experienced, 

skilled installer or service agency must perform 

installation and service.

WARNING

This boiler must be properly vented.
This  boiler  needs  fresh  air  for  safe  operation 

and must be installed so there are provisions for 

adequate combustion and ventilation air.

A. 

Installation Conformance

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 

must conform to the Standard for Controls and Safety 

Devices for Automatically Fired Boilers, ANSI/ ASME 

CSD-1.

B. 

Boiler Foundation

Before  uncrating,  the  boiler  location  should  be 

prepared.  The boiler should set upon a good level 

concrete floor.  If the boiler is not level or the floor is 

not in good condition, a concrete foundation should 

be built, the dimensions being larger than the outside 

dimensions of the boiler base.  A 4” high housekeeping 

pad is suggested.

WARNING

Do not install boiler on combustible flooring.

C.  Clearance and Serviceability

See Figure 4 and Table 2 for minimum clearances to 

walls, ceilings, or obstructions.  These clearances are 

intended as a general recommendation only.  Local 

codes must be applied to specific installations and 

the minimum clearances established accordingly.  

Provisions must also be made for service, accessibility 

and clearance for piping and electrical connections.  

Do  not  obstruct  combustion  air  and  ventilation 

openings  with  piping  or  any  other  construction.  

All boilers must be installed in a space that is large 

compared to the boiler.

Summary of Contents for FREE FLEX

Page 1: ...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 WARNING This manual must only be used by a qualified heating installer service technician Read all instructions in this manual before installing Perform ste...

Page 2: ...2 B Boiler Out Procedure 42 C Replacement Boiler Installations 43 D Draining and refilling the boiler system 43 E Boiler Water Treatment 44 VII System Start Up 45 A Concert Boiler Control Display Navigation 45 B System Check 46 C Power the Boiler 46 D Power the Circulators 46 E Pressurize the Fuel System 46 F Boiler Commissioning 46 G Commissioning Free Flex 1000 Free Flex 3000 46 H Dual Fuel Free...

Page 3: ... Maintenance and Inspection 52 Figure 15 Free Flex 1000 3000 Ignition Assembly 53 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...

Page 4: ...gram 76 Figure 33 Free Flex 2000 To Free Flex 3000 208 460 VAC Three Phase Wiring Diagram 78 Figure 34 Free Flex 1500 To Free Flex 3000 High Turndown 120 460 VAC Single or Three Phase Wiring Diagram 80 Figure 35 Free Flex 1500 To Free Flex 3000 Dual Fuel 120 460 VAC Single or Three Phase Wiring Diagram 84 Figure 36 Free Flex 3500 To Free Flex 6000 208 460 VAC Three Phase Wiring Diagram 88 Figure 3...

Page 5: ... 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 ...

Page 6: ...nal injury hazards B 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 must conform to the Standard for Controls and Sa...

Page 7: ...orical performance characteristics and annunciating boiler alarm lockout conditions 1 Boiler On Off switch 2 Manual gas shutoff valve The boiler is equipped with two manual gas shut off valves one located on the incoming gas supply line outsideoftheboiler andtheotherdownstream of the main gas valve 3 Main gas supply connection 4 Pressure relief valve The pressure relief protects the heat exchanger...

Page 8: ...e gauge 14 Boiler water pressure gauge References 16 to 18 are only used on Free Flex 3500 Free Flex 6000 15 Boiler Hand Off Auto 16 Push Button Display The display provides easy access for viewing and adjusting boiler operational parameters and provides alarm lockout codes 17 Temperature Display Provides for temperature set points and actual temperature Figure 1 Free Flex 1000 External Boiler Con...

Page 9: ...e 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 B Boiler Foundation Before uncrating the boiler location should be prepared The boil...

Page 10: ...Boiler Burner End 24 32 43 CH From Chimney or Vent Collector measured horizontally 18 18 18 CV From Chimney or Vent Collector measured vertically 18 18 18 D Rear of Boiler opposite burner end 6 6 6 EL Left Side tube access side on standard con struction 16 23 23 ER Right Side tube access side on standard construction Free Flex 3500 6000 6 6 23 EC Free Flex 1500 3000 only N A 23 N A Figure 4 Cleara...

Page 11: ...relief valve and the appliance or in the discharge piping Avoid over tightening as thiscandistortvalveseats Allpipingfromthe safety relief valve s must be independently supported with no weight carried by the valve NOTICE If the relief valve discharges periodically this may be due to thermal expansion in a closed water supply system Contactthewatersupplierorlocal plumbing inspector on how to corre...

Page 12: ...by draining the condensate through a limestone bed Consult Thermal Solutions or a chemical treatment company for buffering system CAUTION Failure to properly pipe the condensate system will greatly reduce boiler life Do not install plugs caps or valves on condensate piping Do not manifold boiler condensate and vent drains together Do not crimp condensate lines or reduce drain line inner diameter s...

Page 13: ...d solely from an indoor source is discouraged No dimension for a round or rectangular opening shall be less than 3 D Gas Supply Connections The installation must conform completely to the requirements of the authority having jurisdiction or in the absence of such requirements shall conform in the U S to the current National Fuel Gas Code ANSI Z223 1 1984 or in Canada to the current Natural gas and...

Page 14: ...vided to replace the exhausted air c Each boiler and other appliance must be interlocked to prevent operation when the mechanical air supply system is not in operation d If the combustion air is provided by a buildings mechanical ventilation system the system shall be sized to provide the specified combustion air in addition to the ventilation air requirements 4 Louvers and Grilles are not permitt...

Page 15: ...ng s in walls for combustion air i NFPA 54 National Fuel Gas Code ANSI Z223 1 j ASME CSD 1 Controls and Safety Devices for Automatically Fired Boilers k ASME Section VI Recommended Rules for Care and Operation of Heating Boilers l BOCA National Mechanical Code WARNING Donotlocateairintakeswherepetroleumdistillates CFC s detergents volatile vapors or any other chemicals are present Severe boiler co...

Page 16: ...gas condensation as AL29 4C c Flue system and material shall be certified to UL1738 Venting Systems For Gas Burning Appliances Categories II III and IV 5 Do not reduce the diameter of the vent pipe The vent pipe must not be smaller than the vent connector on the boiler WARNING WARNING This appliance must not be installed in a room under negative pressure These direct vent gas fired appliances are ...

Page 17: ... F891 cellular coreCPVCorRadel polyphenolsulfone isprohibited All condensate that forms in the vent must be able to drain back to the heat exchanger 8 This appliance operates under conditions that permit condensation in the heat exchanger and the flue gas venting This appliance shall be installed so as to prevent accumulation of condensate and where necessary have means provided for drainage of co...

Page 18: ...5 3 0 9 100 45 7 4000 12 315 0 100 45 7 12 315 3 0 9 100 45 7 4500 14 356 0 100 45 7 14 356 3 0 9 100 45 7 5000 14 356 0 100 45 7 14 356 3 0 9 100 45 7 5500 14 356 0 100 45 7 14 356 3 0 9 100 45 7 6000 14 356 0 100 45 7 14 356 3 0 9 100 45 7 Note Contact factory for assistance on maximum vent length applications This table applies to all listed vent combustion air system opetoins Table 5 Vent and ...

Page 19: ...Meters 8 200 2 22 0 068 25 7 62 11 11 3 386 2591 10 250 0 68 0 207 7 14 2 176 3 57 1 088 1658 12 315 0 267 0 081 2 7 0 822 1 35 0 411 1152 Free Flex 3500 Pressure Drop in Equivalent Feet Meters 10 250 0 455 0 138 4 55 1 386 2 727 0 831 1935 12 315 0 172 0 052 1 724 0 525 0 862 0 252 1344 14 356 0 08 0 024 0 77 0 234 3 85 1 173 987 Free Flex 4000 Pressure Drop in Equivalent Feet Meters 10 250 0 95 ...

Page 20: ...ivalent Feet Meters 8 200 1 19 0 362 12 5 3 81 5 9 1 798 1895 10 250 0 37 0 112 3 7 1 127 1 85 0 563 1213 12 315 0 14 0 042 1 41 0 429 0 7 0 213 842 Free Flex 3500 Pressure Drop in Equivalent Feet Meters 10 250 0 39 0 118 3 92 1 194 1 96 0 597 1414 12 315 0 15 0 045 1 49 0 454 0 75 0 228 982 14 356 0 07 0 021 0 67 0 204 0 33 0 1 722 Free Flex 4000 Pressure Drop in Equivalent Feet Meters 10 250 0 5...

Page 21: ...0 1809 1322 14 Table 9 Approved Vent Manufacturers and Materials Brand Material Model Heat Fab Stainless Steel Saf T Vent EZ Seal Z Fles Nova Flex Group Stainless Steel Poly propylene Z Vent Z DENS DuraVent Polypropylene PolyPro Single Wall Rigid Centrotherm Polypropylene InnoFlue SW Rigid Factory supplied flue connection Adapters are required to transition to alternate vent materials or manufactu...

Page 22: ...t 1000 1500 2000 8 Tee 9890TEE 2SVST08 Elbow 9814TERM 2SVEE0890 Straight 9892 2SVSTPX08 2500 3000 10 Tee 91090TEE 2SVST10 Elbow 91014TERM 2SVEE1090 Straight 91092 2SVSTPX10 3500 4000 12 Tee 91290TEE 2SVST12 Elbow 91214TERM 2SVEE1290 Straight 91292 2SVSTPX12 4500 5000 5500 6000 14 Tee N A 2SVST14 Elbow N A 2SVEE1490 Straight 91492 2SVSTPX14 Table 13 Polypropylene Vent and Intake Terminations Free F...

Page 23: ... Tee Table 12 Table 13 Figure 8 Vent Horizontal Sidewall Tee or Straight 5 Intake Horizontal Sidewall Tee Vent Vertical Roof Tee or Straight 6 Intake Vertical Roof Tee or 2 Elbows Figure 9 Figure 10 Vent Vertical Roof Tee or Straight Two Pipe CPVC vent Galva nized Steel or PVC intake 7 Intake Horizontal Sidewall Tee or Elbow Figure 8 Vent Horizontal Sidewall Tee or Straight 8 Intake Horizontal Sid...

Page 24: ...s electric meters regulators and relief equipment Do not install vent terminal above or below this equipment 10 Do not locate the vent terminal under decks or similar structures 11 Top of terminal must be at least 24 in 600 mm below ventilated eaves soffits and other overhangs In no case may the overhang exceed 48 in 1200 mm Where permitted by the authority having jurisdiction and local experience...

Page 25: ...25 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Figure 7 Vent Terminal Clearances ...

Page 26: ...cm for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 4 ft 1 2 m below or to side of opening 1 ft 300 mm above opening K Clearance to a mechanical air supply inlet 6 ft 1 83 m 3 ft 91 cm above if within 10 ft 3 m horizontally L Clearance above paved sidewalk or paved driveway located on public property 7 ...

Page 27: ...Terminations Combustion Air Intake Terminations Roof Sidewall Sidewall Roof Notes Do not use Louvers for direct vent systems One appliance per gooseneck termination Vent and intake piping must not share the same gooseneck All terminations should have Bird Rodent Screens Do not use rain caps Rain will drain through boot tee or condensate drain Tee Termination Vertical Run 20 45 Elbow Terminated Dow...

Page 28: ...ation of flashing and storm collar to prevent moisture from entering the structure c Use appropriately designed vent flashing when passing through roofs Follow flashing manufacturers instructions for installation d Extend combustion air pipe to maintain minimum vertical and horizontal distance of 12 in 300 mm from roof surface or from the maximum snow level CAUTION CAUTION Reliable operation of th...

Page 29: ...eat exchanger or a boot tee with a drain The venting system must be free to expand and contract and must be supported in accordance with installation instructions included by the original component manufacturers whenever applicable Polypropylene pipe sections must be disengaged 1 4 to 5 8 in 6 mm to 16 mm per joint to allow for thermal expansion 4 Pipe Diameters min 12 in min Above Snow Line Grade...

Page 30: ...tions must have bird rodent screens 2 If Possible Install Sidewall venting on a wall away from prevailing wind 3 For roof terminations install vent terminal downstream of prevailing winds relative to intake terminal 4 It is recommended to use tee terminations with a vertical run in extra windy areas NOTICE NOTICE The required spacing between vent and combustion air terminals is to prevent flue gas...

Page 31: ...ty damage or 3 Where condensate vapor could cause damage or could be detrimental to the operation of regulators relief valves or other equipment WARNING WARNING Moisture and ice may form on the surface around vent termination To prevent deterioration surface must be in good repair sealed painted etc Do notallowlowspotsin theventwherecondensate may pool Use specified vent and combustion air pipe di...

Page 32: ...Notes 1 D Vent Pipe Diameter 2 All terminations must have bird rodent screens 3 If Possible Install Sidewall venting on a wall away from prevailing wind 4 For roof terminations install vent terminal downstream of prevailing winds relative to intake terminal 5 It is recommended to use tee terminations with a vertical run in extra windy areas NOTICE NOTICE The required spacing between ventandcombust...

Page 33: ...Maximum equivalent vent length of flexible polypropylene liner is 48 ft 14 6 m WARNING WARNING Asphyxiation Hazard Vent systems made by listed PP vent system manufacturers rely on gaskets for proper sealing When this type of vent system is used take the following precautions Make sure that gasket is in position and undamaged in the female end of the pipe Make sure that both male and female pipes a...

Page 34: ...ir and ventilation air The air supply requirements below are a summation specific to this boiler 3 Air Supply Requirements for Appliances having an input exceeding 400 MBH a Ventilation Air an opening for ventilation air at the highest point that opens to the outdoors shall provide Ventilation of the space The cross sectional area of this opening shall be at least 10 of the area required for combu...

Page 35: ...n Standard is not meant to be all inclusive Reading the entire Standard is strongly suggested The final approval of all system designs must be acceptable to the authority having jurisdiction i VentingforCategoryIVappliancesshallbeas specified or furnished by the manufacturer of the listed appliance This boiler is a Category IV appliance requiring the use of special vent that is certified ii A spec...

Page 36: ... a chimney flue that is servicing a separate appliance designed to burn solid fuel Do not insulate polypropylene vent pipes Excessive heat could cause premature vent pipe failure 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 fle...

Page 37: ...mmon 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 bui...

Page 38: ...d heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS d A final inspection by the state or local gas inspector of the sidewall horizontally vented equipment shall not be performed until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for...

Page 39: ...ct in the circuit A service switch is recommended and may be required 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 17 for available voltages Table 17 Electrical Requirements Free Flex 1000 Voltage FLA CCA MHP MA 120 1 60 6 6 2 6 46 4 Free Flex 1500 Voltage FLA CCA MHP MA 120...

Page 40: ...3 from the boiler at the front rear and two sides See Table 19 for decibel readings Table 19 Sound Pressure Levels Free Flex Model Decibel Levels Front Rear Tube Side Right Side 1000 68 61 63 64 1500 67 60 61 63 2000 67 60 61 63 2500 62 62 66 61 3000 62 62 66 61 D Pump and Piping Requirements Pump piping and system piping must meet the requirements of local codes and jurisdictions Good engineering...

Page 41: ...500 143 9 2 20 2000 190 16 3 20 2500 238 20 20 3000 285 28 7 20 3500 333 11 33 20 4000 380 15 17 20 4500 428 25 17 20 5000 475 33 5 20 5500 523 37 25 20 6000 570 37 92 20 Note not for sizing constant volume pump 2 Water Flow Rates Primary Secondary Systems a Each boiler connected to a secondary loop of a primary secondary pumping system shall have a constant volume pump sized in accordance with Ta...

Page 42: ... successive zones of the system to waste carrying metal shavings dirt pipe joint compound etc with it Follow with a chemical flush WARNING Be CERTAIN that the chemicals used to flush and boil out the boiler and system contain NO CHLORIDES The boiler is fabricated with austenitic stainless steels that can be severely damaged when exposed to chlorides The removal of pipe chips and other debris from ...

Page 43: ...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 section E Boiler Water Treatment Failure to properly clean...

Page 44: ...d in addition to the chemical treatment of the boiler Water softening removes calcium and magnesium the primary causes of hard boiler scale 2 Continuous Monitoring a Water treatment should be checked and maintained according to Table 27 whenever the boiler is operating The boiler operator should be sure that the boiler is not operating for long periods without proper water treatment b Water treatm...

Page 45: ...th this boiler before attempting start up A Concert Boiler Control Display Navigation This boiler is equipped with a color touch screen display which presents information and control options in a page manner Pages are arranged in a tree structure through which the user navigates up and down to arrive at the desired function The page descriptions and a complete list of the available control paramet...

Page 46: ...ctions I through VI shall be completed before commissioning the boiler DANGER Failure to properly adjust excess air will result in unsafe levels of carbon monoxide Variations in venting or combustion air pressure and temperature will change excess air Adjust excess air levels so that variation in venting or combustion air pressures and temperatures caused by change of seasons wind conditions openi...

Page 47: ...t the O2 level within 6 5 to 7 0 c For boilers specified to be less than 9 ppm NOx adjust the O2 level within 7 0 to 9 0 19 Note For O2 High Fire adjustment reference only the combustion system that is on the boiler SeeFigure13andFigure14todetermine the boiler s combustion system 20 O2 level must be set at high fire with all jacket doors installed and front cabinet door closed a Dungs High Fire O2...

Page 48: ...offs and nuisance flame failures 21 Verify O2 repeatability by commanding the boiler to high fire and low fire as many times as required repeating Step 20 as necessary 22 Oncetheboilerisoperatingwithinthespecified high and low fire ranges record emissions flue draft and other important data on the installation and startup report see Appendix C 23 Perform tests on each of the components listed in T...

Page 49: ...00 reset the pilot low gas pressure switch and reset the gas pressure lockout 7 Increase the high gas pressure switch setting to 14 w c 8 Cycle the boiler a For Free Flex 1500 Free Flex 3000 the boiler should lockout on flame failure or ignition failure Boiler may recycle once if there was an ignition failure b For Free Flex 3500 Free Flex 6000 verify the pilot has lit then the boiler should locko...

Page 50: ...e less than 9 ppm NOx adjust the O2 level within 7 0 to 9 0 22 Verify O2 repeatability by commanding the boiler from 20 to 100 and the intermediate points in between as many times as required repeating Step 21 as necessary 23 Oncetheboilerisoperatingwithinthespecified high and low fire ranges record emissions flue draft and other important data on the installation and startup report see Appendix I...

Page 51: ...eset blocked condensate switch lockout Hard Lockout Blocked Conden sate Switch Vestibule Thermal Fuse Disconnect one wire of the vestibule thermal fuse Cycle the boiler Re connect wiring to the blocked condensate switch Reset vestibule thermal fuse lockout Hard Lockout Vestibule Ther mal Fuse Low Water Cutoff With the boiler running push and hold the LWCO test button until the boiler control shuts...

Page 52: ...ns and warnings contained in all of the component instruction manuals If any electrical wires are disconnected during service clearly label the wire and ensure that the wires are reconnected properly Never jump out or bypass any safety or operating control or components of this boiler WARNING Assure that all safety and operating controls and components are operating properly before placing boiler ...

Page 53: ...4 Inspect the ignition rod for carbon build up 5 Inspect lens of the ultra violet UV scanner and remove any debris with soft cloth and make sure that hole is clear from scanner to burner 6 Replace air filter F Ignition Assembly Cleaning 1 Disconnect power and shut off the external manualgasvalvetotheboilerpriortoremoving the ignition assembly 2 When removing the igniter extra caution must be taken...

Page 54: ...TICE Performing a regular boiler inspection will prolong the life of the heat exchanger and ensure optimal function and energy efficiency For best practices adhere to the general guidelines outlined in the service and maintenance section of this manual 1 Inspect the boiler Use the following steps to identify a potential tube leak and to minimize possible damage to the boiler and other equipment as...

Page 55: ...for Tube Inspection Free Flex 1000 Figure 18 Panel Removal in Preparation for Tube Inspection Free Flex 1500 Free Flex 3000 3 2 2 4 4 1 ITEM DESCRIPTION 1 JACKET SIDE PANEL 2 FLUE DOOR CLAMPS 3 FURNACE DOOR 4 TUBE CLAMPS 1 3 4 5 6 6 2 ITEM DESCRIPTION 1 JACKET SIDE PANEL 2 CENTER RAIL 3 FLUE DOOR CLAMPS 4 CONVECTION DOOR 5 FURNACE DOOR 6 TUBE CLAMPS ...

Page 56: ...he tube two or three times with a hammer to help loosen the tube end in the upper and lower header 4 Pull lower tube end Wedge the tube puller under the flange of the tube Drive the tube puller with several blows with a hammer on the end of the handle Alternate with downward blows to lift tube end 5 Clear tube end from the header Continue driving wedge under and leveraging flange up until it pops ...

Page 57: ...hole Pipe dope may also be applied to the tube end Cutting oil may be mixed with the pipe dope for easier application 8 Insert both ends of the tubes into the headers Insert the lower tube end into the bottom header first Then insert the top tube end into the top header Insert all replacement tubes before driving them 9 Drive the upper and lower tube ends DO NOT drive the tube ends down to the fla...

Page 58: ...st be reduced to zero before adjusting tube s Adjusting tubes under pressure could result in serious personal injury 12 Reinstall all flue access doors door clamps and jacket panels 13 Perform startup check prior to putting boiler back into operation J Safety and Operating Controls All of the safety control devices listed in Table 30 are logically linked to the Concert Boiler Control that supervis...

Page 59: ...f Valve If the pressure inside the boiler exceeds the fixed set point the valve opens mechanically and discharges water The valve remains open until the pressure inside the boiler drops below the set point High and Low Gas Pressure Switches If the gas pressure reaches a point above or below the adjustable set point the contacts of the switch open and power is interrupted to the control circuit tha...

Page 60: ...oltage fuse Replace if necessary Check for bad transformer or bad 24 Vdc power supply Replace if necessary Blinking Green power light on Control Control Fault The green light is connected to internal power supply The power supply is repeatedly starting and stopping not normal making the light flash The microprocessors are not running Try disconnecting all terminals except 24 Vac to power the contr...

Page 61: ... 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 32 Maximum Gas Capacity Of Schedule 40 Pipe Pipe Length in Equivalent Feet Pipe Size NPT 1 1 1 4 1 1 2 2 2 1 2 3 4 10 273 514 1060 1580 3050 ...

Page 62: ...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 screwed fittings and for screwed flanged and welded valv...

Page 63: ...ayed to complete log in Advance to the Parameter 500 series a Blocked Flue Air Switch i Set Parameters 502 00 Air and 503 00 VSD to match P9 s Air and VSD settings After pressing Enter the Air Damper and VSD will adjust to these settings ii Use a Multimeter set to Ohms or Continuity With Multimeter leads placed on the switch terminals turn air switch adjustment slowly counter clockwise until the c...

Page 64: ...am LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Appendix C Venting Diagrams Figure 21 Typical Horizontal Vent Piping Figure 22 Typical Vertical Pressurized Venting ...

Page 65: ...C www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Appendix D Combustion Air Diagrams Figure 23 Typical Horizontal Air Intake Piping Figure 24 Typical Vertical Air Intake Piping ...

Page 66: ...ent Purge Valve System Circulator Outlet Supply Makeup Water Check Valve Pressure Reducing Valve Expansion Tank Isolation Valve Boiler Circulator Check Valve Y Strainer 1500 3000 model shown Inlet Outlet Connections are similar on the 3500 6000 models NOTICE 1 These are suggested piping configurations It is the installer s responsibility to conform to local codes and ordinances for additional requ...

Page 67: ... Outlet Connections are similar on the 3500 6000 models System Circulator Check Valve Pressure Reducing Valve Motorized Isolation Valve Makeup Water Outlet Supply Y Strainer Check Valve Isolation Valve Inlet Return Air Vent NOTICE 1 These are suggested piping configurations It is the installer s responsibility to conform to local codes and ordinances for additional requirements 2 Pressure relief v...

Page 68: ...let Outlet Connections are similar on the 3500 6000 models Air Vent Purge Valve System Pump Inlet Return Check Valve Pressure Reducing Valve Isolation Valve Boiler Circulator Check Valve Y Strainer Expansion Tank Outlet Supply Makeup Water NOTICE 1 These are suggested piping configurations It is the installer s responsibility to conform to local codes and ordinances for additional requirements 2 P...

Page 69: ...tlet Connections are similar on the 3500 6000 models Air Vent Purge Valve System Circulator Outlet Supply Makeup Water Check Valve Pressure Reducing Valve Boiler Circulator Check Valve Y Strainer Isolation Valve Expansion Tank Inlet Return NOTICE 1 These are suggested piping configurations It is the installer s responsibility to conform to local codes and ordinances for additional requirements 2 P...

Page 70: ...hown Inlet Outlet Connections are similar on the 3500 6000 models Inlet Return Purge Valve Expansion Tank Isolation Valve Boiler Circulator Check Valve Y Strainer Air Vent Pressure Reducing Valve Check Valve Makeup Water DHW Circulator System Circulator Tempering Valve Hot Water Cold Water Check Valve Outlet Supply NOTICE 1 These are suggested piping configurations It is the installer s responsibi...

Page 71: ... Hd 100F 57 1 15 100F 67 0 42 100F 76 0 42 100F 86 0 42 90F 63 1 42 90F 74 0 50 90F 84 0 58 90F 75 0 50 80F 71 1 79 80F 83 0 67 80F 95 0 92 80F 107 0 58 70F 81 2 34 70F 95 0 92 70F 109 1 17 70F 122 0 67 60F 95 3 19 60F 111 1 17 60F 127 1 42 60F 143 0 92 50F 114 4 59 50F 133 1 50 50F 152 2 42 50F 171 2 92 45F 127 5 67 45F 148 2 08 45F 169 2 58 45F 190 4 17 40F 143 7 18 40F 166 2 60 40F 190 3 17 40F...

Page 72: ...765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Appendix G Wiring Diagrams Note Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy Figure 30 Free Flex 1000 Wiring Diagram Page 1 A ...

Page 73: ...73 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 1 B ...

Page 74: ...3 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Figure 31 Free Flex 1500 To Free Flex 3000 115 VAC Single Phase Wiring Diagram Page 1 A Note Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy ...

Page 75: ...75 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 1 B ...

Page 76: ...6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Figure 32 Free Flex 1500 To Free Flex 3000 208 230 VAC Single Phase Wiring Diagram Page 1 A Note Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy ...

Page 77: ...77 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 1 B ...

Page 78: ... 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Figure 33 Free Flex 2000 To Free Flex 3000 208 460 VAC Three Phase Wiring Diagram Page 1 A Note Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy ...

Page 79: ...79 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 1 B ...

Page 80: ...Chili Ave Peru IN 46970 sales bryansteam com Figure 34 Free Flex 1500 To Free Flex 3000 High Turndown 120 460 VAC Single or Three Phase Wiring Diagram Page 1 A Note Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy ...

Page 81: ...81 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 1 B ...

Page 82: ...82 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 2 A ...

Page 83: ...83 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 2 B ...

Page 84: ...N Chili Ave Peru IN 46970 sales bryansteam com Figure 35 Free Flex 1500 To Free Flex 3000 Dual Fuel 120 460 VAC Single or Three Phase Wiring Diagram Page 1 A Note Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy ...

Page 85: ...85 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 1 B ...

Page 86: ...86 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 2 A ...

Page 87: ...87 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 2 B ...

Page 88: ... 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Figure 36 Free Flex 3500 To Free Flex 6000 208 460 VAC Three Phase Wiring Diagram Page 1 A Note Wiring diagrams are for reference only please refer to the wiring shipped with the boiler for accuracy ...

Page 89: ...89 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 1 B ...

Page 90: ...90 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 2 A ...

Page 91: ...91 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 2 B ...

Page 92: ...h J13 Isolation Valve End Switch J14 External Limit J15 Spare Limit 32 J16 P30 4 PCB 03 J12 25 26 24 28 29 27 31 30 23 P30 3 79 80 RED ORG Low GPS C NO C NO Low PGPS NG LP CR2 7 11 CR3 7 11 NG High GPS C NC LP High GPS C NC CR2 6 10 CR3 6 10 P1 2 P1 2 P1 1 P1 3 Select Fuel NG LP A M1 M2 L1 L2 M3 L3 25 KVA Control Circuit Transformer C0250E5EFB X1 X2 X3 120vac GND Connect to V C P Power Supply A B ...

Page 93: ...93 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 1 B ...

Page 94: ...94 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 2 A ...

Page 95: ...95 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Page 2 B ...

Page 96: ...96 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Notes ...

Page 97: ...97 Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Notes ...

Page 98: ...riod Labor for removal and or installation is not included B Warranty The owner must notify the original installer of the Product and Seller Attention Thermal Solutions P O Box 3244 Lancaster PA 17604 3244 in writing within the Warranty Period providing a detailed description of all claimed defects Transportation to a factory or other designated facility for repairs of any products or items allege...

Page 99: ..._______ Control ____________ Water Temp SP1 ______O F RWT ______O F Ducted Air ________ AL29 4C Vent Material ______ Vent Dia _______ Rain Cap ______ Feet Vertical ________ Feet Horizontal ______Elbows Tees _______________________ Operating Parameter Setting Gas Supply Pressure iwc psi at inlet to boiler gas train all units on static high fire Read at Low Fire High Fire Fan Speed rpm Fan Speed Lig...

Page 100: ...Bryan Steam LLC www bryanboilers com Phone 765 473 6651 783 N Chili Ave Peru IN 46970 sales bryansteam com Bryan Steam LLC 783 N Chili Ave Peru IN 46970 Phone 765 473 6651 www bryanboilers com ...

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