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:
iii
3.5.4
Pump and Piping Requirements ........................................................................................................... 24
3.5.4.1
Water Flow Rates (Variable Primary Pumping Systems) .................................................. 25
3.5.4.2
Water Flow Rates (Primary / Secondary Systems) .............................................................. 25
3.5.4.3
Water Flow Rates (Constant Volume Primary Pumping Systems) ................................ 27
3.5.4.4
Water Flow Rates for Glycol .......................................................................................................... 27
3.6
Before Placing Boiler In Operation ............................................................................................................... 27
3.6.1
Pre-Boil Out Flushing Of System ........................................................................................................... 27
3.6.2
Boil Out Procedure ..................................................................................................................................... 27
3.6.3
Replacement Boiler Installations.......................................................................................................... 28
3.7
Draining and refilling the boiler & system ................................................................................................ 28
3.7.1
Filling The System ....................................................................................................................................... 28
3.7.2
Hydrostatic Test Of Boilers And System ............................................................................................ 28
3.8
Boiler Water Treatment .................................................................................................................................... 29
3.8.1
Purpose of water treatment .................................................................................................................... 29
3.8.2
Objectives ....................................................................................................................................................... 29
3.8.3
Water softener .............................................................................................................................................. 29
3.8.4
Continuous Monitoring ............................................................................................................................. 29
4
SYSTEM START-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 Maintenance:......................................................................................................................................... 37
5.1.1
DAILY: .............................................................................................................................................................. 37
5.1.2
WEEKLY: ......................................................................................................................................................... 38
5.1.3
MONTHLY: ..................................................................................................................................................... 38
5.1.4
ANNUALLY: .................................................................................................................................................... 38
5.2
Ignition Assembly Cleaning ............................................................................................................................. 38
5.3
Burner Assembly Cleaning ............................................................................................................................... 39
5.4
Heat Exchanger Cleaning .................................................................................................................................. 39
5.5
Tube Replacement Procedure ........................................................................................................................ 40
5.6
Safety and Operating Controls ........................................................................................................................ 44
5.7
Troubleshooting ................................................................................................................................................... 45
Appendix A Sizing Gas Piping ........................................................................................................................................... 48
Appendix B Vent and Combustion Air Pressure Drop Data ................................................................................. 50
Appendix C Installation & Startup Report ................................................................................................................... 51
Appendix D Venting Diagrams ......................................................................................................................................... 52
Appendix D.1 Typical Horizontal Vent Piping ....................................................................................................... 52
Appendix D.2 Typical Vertical Pressurized Venting ........................................................................................... 53
Appendix E Combustion Air Diagrams ......................................................................................................................... 54
Appendix E.1 Typical Horizontal Air Intake Piping ............................................................................................ 54
Appendix E.2 Typical Vertical Air Intake Piping .................................................................................................. 55
Appendix F Boiler Piping Diagrams ............................................................................................................................... 56
