Bryan Boilers D Series Manual

Installation
Operation
Service Manual
for
Atmospheric Water
Boilers
E-Mail: [email protected] / Internet: www.bryanboilers.com
BRYAN BOILERS
783 N. CHILI AVENUE, PERU, INDIANA 46970
Telephone: [phone] / Fax: [phone]

INSTALLATION INSTRUCTIONS
ATMOSPHERIC
WATER BOILERS
NOTE:
• Please read all of instruction manual before attempting installation.
• Insurance and local or state regulatory codes may contain additional or more stringent requirements
than those contained in this manual. Installation must conform to these codes and any other
authority having jurisdiction.
1.1 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
in good condition, a concrete foundation should
be built, the dimensions larger than the outside
dimensions of the boiler base.
DO NOT INSTALL BOILER ON COMBUSTIBLE
FLOORING. The only exception to this is UL
Labeled F -Series boilers which may be installed
on combustible flooring.
IMPORTANT
If the boiler is installed directly on a concrete floor
where it is important that the floor be kept cool
(such as an upper floor or mezzanine or when
sitting over wiring conduits) set the boiler up on
insulating tile or steel framework so that air may
circulate underneath. For atmospheric gas fired
boilers, it is advisable to build up an insulating
floor under the boiler using high temperature
mineral fiber board at least 1 1/2" thick.
1.2 CLEARANCES
See Table 1 for minimum clearances to wall,
ceilings, or obstructions. The clearances in Table
1 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 which is large
compared to the boiler. Only UL Labeled F-Series
boilers are suitable for installation on combustible
flooring.
NOTE
ADHERE TO ALL APPLICABLE LOCAL CODES
REGARDING BOILER INSTALLATION AND
CLEARANCES.
1.3 UNCRATING THE BOILER
Uncrate the boiler near its permanent location.
Leave it on the bottom crating until ready to place
it permanently. Leave the plastic shroud on the
boiler until all piping work is complete, cutting
holes in the plastic for access to connections.
Remove the bolts attaching the boiler to the crate
at the underside of the bottom crating. Lift or slide
the boiler off of the bottom crating into position.
Be careful not to tip the boiler up on one corner or
side, which could cause damage to jacket.

MINIMUM CLEARANCES
NOTE: These boilers are intended to be installed in a room which is large compared to the size of the boiler.
They are not intended for alcove installation and are suitable for installation on non-combustible flooring
only.
DIMENSION
D-SERIES F-SERIES1CL-SERIES K-SERIES RV, RW & AB SERIES
WATER/
STEAM
TO 50#
STEAM
OVER
50#
WATER
/STEAM
TO 50#
STEAM
OVER
50#
WATER
/STEAM
TO 50#
STEAM
OVER
50#
WATER
/STEAM
TO 50#
STEAM
OVER
50#
WATER
/STEAM
TO 50#
STEAM
OVER
50#
A 18" 36" 18" 48" 24" 24" 18" 36" 24" 24"
B 24" 24" 48" 96" 48" 36" 48" 24" 48" 48"
CV& CH18" 36" 18" 36" 24" 24" 24" 24" 24" 24"
D 48" 96" 18" 36" 24" 24" 24" 24" 24" 24"
EL& ER24" 24" 18" 36" 24" 24" 24" 24" 32" 32"
1 - F-Series boilers are approved for installation on combustible flooring. Do not install on carpeting.
A - Clearance above boiler
B-Frontofboiler
C
V- Clearance from gas vent, measured vertically above pipe
C
H- Clearance from gas vent, measured horizontally or below pipe
D - From back of boiler
E
L- Left side of boiler
E
R- Right side of boiler
These clearances are general minimum clearances. Local codes may dictate larger clearances.

1.4 BOILER CONNECTIONS
1.4.1 GENERAL
Do not run any pipes along the access panel side of
the boiler. Maintain clearances as shown on the
dimensional drawing for servicing of the boiler tubes.
Provide at least 36" from the gas train and burner,
unless a larger dimension is indicated on the
dimensional. All piping should be designed and
installed to avoid any loadings on the boiler
connections or piping.
1.4.2 FLOW CONNECTIONS
The system supply and return flow connections are
shown on the boiler dimensional drawing in this
manual. A gate valve and union should be on the
boiler outlet and inlet lines. This allows the boiler to be
isolated from the heating system for draining and
servicing. Use a tee, nipple, and cap on the boiler
inlet line to allow inspection and cleaning.
1.4.3 SAFETY RELIEF VALVE(S)
A connection is provided in the top of the boiler for the
relief valve. The relief valve discharge piping must be
the same size as the relief valve discharge opening.
Avoid over-tightening as this can distort valve seats.
All piping from relief valve must be independently
supported with no weight carried by the valve.
1.4.4 EXPANSION TANK CONNECTION
A connection is provided in the top of the boiler for
connecting piping to the expansion tank. This piping
should be installed as to avoid air entrapment in the
boilers.
1.4.5 DRAIN CONNECTION
A drain valve must be installed off of the boiler drain
connection, the same pipe size as this connection, to
allow draining of the boiler.
1.4.6 INDIRECT WATER HEATING BOILERS
When the boiler is to be used only for heating potable
(domestic) water or swimming pool water, the heating
system connections discussed above are capped.
The relief valve connections are still required. Water
connections are made only to the indirect heat
exchanger(s), according to the piping drawing
included in this manual. An automatic boiler fill valve
is provided with the boiler. This valve must be
connected to the fresh water system. With some
units, this connection is made to the heat exchanger
at the factory.
1.5 GAS SUPPLY CONNECTION - ATMOSPHERIC BOILERS
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 Installation Code for Gas Burning
Appliances and Equipment (CAN/CGA B149.1-
M91), or Oil Burning Equipment (CSA B139-
M91), and applicable regional regulations for the
class; which should be followed carefully in all
cases.
Drip leg must be installed on gas supply piping.
Consult the local gas utility company for
inspection and authorization of all gas supply
piping and flue connections.
The regulator vent line must be vented to outside
of building on any boiler equipment with electric
gas pilot ignition.
1.5.1 DRIP LEG
A drip leg, or sediment trap, must be installed in
the gas supply line. See Fig. 1.5A. The gas line
must be connected to a supply main at least as
large as the gas train connection at the boiler.
This connection should be made with a union so
that the boiler gas train components and burner
may be easily removed for service.
1.5.2 GAS PIPING LEAK TEST
After completion of the gas piping hookup, the
installation must be checked for leaks, using a
soap and water solution. Disconnect the boiler
and gas train from the gas supply piping during
any pressure testing.

1.5.3 VENTING OF GAS TRAIN COMPONENTS
Gas pressure regulator - The regulator must be
vented to the outside air, using minimum 1/4"
tubing or pipe. The vent line should terminate in a
downward direction to be free of restriction.
Diaphragm gas valves (V48A or V88A) - The vent
line off of these gas valves must be vented to
outdoors, the same as the regulator.
Normally open vent valves - These valves must
be piped to outdoors using pipe no smaller than
that of the valve.
Gas pressure switches - Vent these switches to
outdoors using a minimum of 1/4" tubing or
piping.
FIGURE 1.5A: GAS BURNER CONNECTION
NOTE: USE PIPE COMPOUND THAT IS RESISTANT TO THE ACTION OF LIQUID PETROLEUM GAS. DO NOT
USE TEFLON TAPE.
1.6 ELECTRICAL CONNECTION
IMPORTANT:All electrical connections must
conform to the National Electrical Code and to all
other applicable State and Local Codes. Atmospheric
boilers require a 120 volt, single phase power
connection plus ground. See boiler wiring
diagram and equipment list for details.
Equipment Grounding - The boiler must be grounded
in accordance with the American National Standard
Electrical Code, ANSI/NFPA #70-1981.
1.7 COMBUSTION AIR SUPPLY
IMPORTANT:Positive means for supplying an
ample amount of outside air, allowing complete
combustion of the gas, must be provided.
Movable combustion air dampers, automatic or
manually adjustable, must be electrically interlocked
with the boiler to prevent boiler operation if the
dampers are closed.
Combustion air openings must never be blocked or
obstructed in any manner.
The boiler room must be at a positive or neutral
pressure relative to the outdoors. A negative in the
boiler room will result in downdraft problems and
incomplete combustion due to the lack of air.
WARNING!
Failure to provide an adequate air supply will result in
boiler damage and hazardous conditions in the
building (fire and asphyxiation hazard as well as
equipment damage).
COMBUSTION AIR: Complete combustion of natural
or propane gas requires approximately ten cubic foot
of air (at sea level and 70F) for each 1000 Btu of
boiler input. In reality additional air is required to
achieve complete combustion. Air is also required for
the proper operation of the appliance draft diverter or
barometric damper. The combustion air opening
recommendations below are designed to provide the
air needed for atmospheric gas fired boilers which are
equipped with either draft diverters or barometric

damper. Combustion air openings for boilers which
are equipped with forced draft burners may be
reduced to 70% of that required for atmospheric gas
fired boilers. This is because the forced draft boiler is
not equipped with a draft diverter (so no air is required
for draft control).
COMBUSTION AIR OPENINGS - AREA REQUIRED:
Openings directly through outside wall -
One opening within 12 inches of the ceiling plus one
opening within 12 inches of the floor. Each opening
must have a minimum free area of 1 square inch per
4,000 Btu of total input of all air using appliances in
the room.
Example: A boiler room having two boilers with
500,000 Btu input would require two openings
through an outside wall, and each opening must have
at least 250 square inches of free area.
Openings through vertical ducts -
One duct in the ceiling plus one duct terminating
within 12 inches of the floor. Each opening must have
a minimum free area of 1 square inch per 4,000 Btu
of total input of all air-using appliances in the room.
Example: A boiler room having four boilers with
250,000 Btu input would require two ducts, one in
ceiling and one terminating near the floor, and each
opening must have at least 250 square inches of free
area.
Openings through horizontal ducts -
One duct opening within 12 inches of the ceiling plus
one duct opening within 12 inches of the floor. Each
opening must have a minimum free area of 1 square
inch per 2,000 Btu of total input for all equipment in
the room. NOTE: No rectangular duct may have a
dimension of less than 4 inches.
Example: A boiler room having 1 million Btu total
input would require two ducts, one in ceiling and one
near the floor, each opening having at least 500
square inches of free area.
Ventilation Air: In addition to air needed for
combustion, sufficient air must be supplied for
ventilation, including air required for comfort and
proper working conditions for personnel in the boiler
room. In colder climates, provision should also be
made to heat the boiler room, if necessary, for
personnel comfort.
CAUTION
Protection from combustion air contamination: Where
corrosive or flammable process fumes are present in
the vicinity of the boiler room or the air stream for the
combustion air supply, it is essential that suitable
means be provided for their safe disposal. The boiler
room and the combustion air supply must not be
exposed to the fumes. Such fumes include, but are
not limited to, carbon monoxide, hydrogen sulfide,
ammonia, chlorine, and halogenated hydrocarbons.
NOTE: Halogenated hydrocarbons are particularly
injurious and corrosive after exposure to high
temperatures.
1.8 CHIMNEY, FLUE PIPE & DRAFT CONTROL - ATMOSPHERIC BOILERS
CODE COMPLIANCE
The installation must conform to the requirements of
NFPA 54, the National Gas Code (ANSI Z223.1-
1984), Part 7, "Venting of Equipment", or to the
applicable requirements of all local building codes. For
factory-built and listed chimney systems (such as type
B vent), consult the system manufacturer's
instructions for correct installation procedures. Gas
vents may be of any of the construction types listed in
this manual. No portion of a venting system may
extend into or pass through any circulating air duct or
plenum.
MINIMUM SAFE PERFORMANCE
Venting systems must be designed to develop positive
flow adequate to remove flue gases to the outside
atmosphere. Guidelines are provided in this manual
and in the National Fuel Gas Code, NFPA 54, for
sizing and design of flue gas venting system. For
additional reference to good practice in vent design,
refer to the "Chimney, Gas Vent, and Fireplace
Design" chapter of the ASHRAE Equipment
Handbook.
OUTSIDE VENTS AND CHIMNEYS
Outside uninsulated single wall pipe is not
recommended for use in cold climates for venting gas-
fired appliances since temperature differentials may
cause corrosion in such pipe, as well as poor draft on
start ups. When local experience indicates that
condensate may be a problem, provisions should be
made to drain off the condensate in the gas vent or
chimney.

ESTIMATING FLUE GAS FLOW RATE (ACFM)
Flue gas volumetric flow rate in SCFM (standard cubic
feet per minute) and ACFM (actual cubic feet per
minute) can be estimated by using the information in
1.8.1A. Divide the Total Input of appliances
connected to the chimney or vent by 1000. Then
multiply this result times the factor listed in the SCFM
and ACFM table. The ACFM data is required for
determining stack exit velocity and induced draft fan
requirements.
ESTIMATING STACK EXIT VELOCITY
First, determine the ACFM for the stack as described
above. Multiply the total ACFM times the Velocity
Factor from the Velocity Table in Table 1.8.1B for the
stack diameter used. The result is the Stack Exit
Velocity in feet per second.
ESTIMATING STACK EMISSIONS
Table 1.8.1C lists approximate emissions of NOx
(oxides of nitrogen) and CO (carbon monoxide). The
table lists both the concentration, in parts per million
(ppm), and the flow rate, in pounds per hour (PPH), of
each compound: Divide the total input of appliances
connected to the chimney or vent by 1,000,000. Then
multiply this result times the value listed in the table for
PPH emissions.
MANUAL REFERENCES
See Figure 1.8.1 for a graphics listing of applicable
sections of this manual for each section of the vent
system.
FIGURE 1.8.1: VENT DESIGN INSTRUCTIONS - REFERENCE
TABLE 1.8.1A: ESTIMATING FLUE GAS VOLUMETRIC FLOW RATE
Approximate Flue Gas VOLUMETRIC FLOW RATE (Per 1000 Btu/hr Input)
(Multiply factor listed times boiler input in MBH)
BOILER TYPE
SCFM Per
1000 Btu/hr INPUT
ACFM Per
1000 Btu/hr INPUT
APPROXIMATE FLUE GAS
TEMPERATURE AT FULL
INPUT
Water & 15# Steam
Boilers
Before Draft
Control
After Draft
Control
Before Draft
Control
After Draft
Control
Before Draft
Control
After Draft
Control
Atmospheric Gas
(Draft Diverter)
Atmospheric Gas
(Barometric D.R.)
0.250
0.250
0.364
0.280
0.462
0.462
0.546
0.474
480F
480F
350F
430F
150# Steam Boilers Before Draft
Control
After Draft
Control
Before Draft
Control
After Draft
Control
Before Draft
Control
After Draft
Control
Atmospheric Gas
(Draft Diverter)
Atmospheric Gas
(Barometric D.R.)
0.250
0.250
0.364
0.280
0.486
0.486
0.602
0.517
550F
550F
400F
500F

TABLE 1.8.1B: STACK EXIT VELOCITY
Estimated STACK EXIT VELOCITY Calculation
(Multiply total ACFM times the velocity factor below velocity in feet per second)
STACK INSIDE
DIAMETER (Inches)
VELOCITY
FACTOR
STACK INSIDE
DIAMETER (Inches)
VELOCITY
FACTOR
STACK INSIDE
DIAMETER (Inches)
VELOCITY
FACTOR
6
7
8
10
12
14
16
0.0849
0.0624
0.0477
0.0306
0.0212
0.0156
0.0119
18
20
22
24
26
28
32
0.00943
0.00764
0.00631
0.00531
0.00390
0.00340
0.00298
34
36
38
40
48
60
0.00264
0.00236
0.00212
0.00191
0.00133
0.00085
TABLE 1.8.1C: ESTIMATING FLUE GAS EMISSIONS
Estimated Emissions (Volumetric Flow Rate Per Million Btu/hr Input)
(Multiply PPH listed times boiler input divided by 1,000,000)
BOILER
TYPE
PARTICULATES NOx CO SOx
PPH per
MBH
PPM PPH per
MBH
PPM PPH per
MBH
PPM PPH per
MBH
PPM
Atmospheric Gas
(Draft Diverter)
Atmospheric Gas
(Barometric D.R.)
N/A
N/A
N/A
N/A
0.115
0.115
70
90
0.120
0.120
75
100
N/A
N/A
N/A
N/A
1.8.2 CLEARANCES
The vent system and draft control devices must
be installed so as to achieve the clearances to
surfaces outlined in Table 1.2.1, Minimum
Clearances chart, in this manual. See also Table
1.8.9 for vent clearances. All clearances must
comply with the National Fuel Gas Code
(NFPA54), and with all
local and state building codes. The clearances
described in this manual are intended to be
general guidelines only, additional requirements
may occur because of local building design
regulations.
1.8.3 PROTECTION AGAINST DOWNDRAFTS
Because of varying wind conditions and proximity
of adjacent structures, the stack termination may
be exposed to severe downdrafts. If this is
anticipated, provision should be made to supply a
stack cap which will prevent downdrafts. The
Breidert type cap will accomplish this.
Downdrafts will cause ignition problems as well
as expulsion of flue products into the boiler room.

1.8.4 BOILER ROOM PRESSURIZATION
The boiler room must be supplied with adequate air
for combustion and for proper operation of draft
control devices (barometric dampers or draft
diverters) as outlined in "Combustion Air Supply",
Section 1.7 of this manual.
WARNING
THE BOILER ROOM MUST BE MAINTAINED AT A
POSITIVE OR NEUTRAL PRESSURE (RELATIVE
TO OUTDOORS) AT ALL TIMES. EXHAUST FANS
OR CONNECTIONS FROM THE BOILER ROOM
TO ZONES OF NEGATIVE PRESSURE (AIR
DUCTS, NEGATIVE PRESSURE ROOMS, ETC.)
WILL CAUSE NEGATIVE PRESSURE IN THE
BOILER ROOM. SUCH CONDITIONS WILL CAUSE
HAZARDOUS OPERATION OF THE BOILER AND
INTRODUCTION OF COMBUSTION PRODUCTS
INTO THE BUILDING AIR.
AND A DRAFT PROVING SWITCH MUST BE
INSTALLED TO PREVENT OPERATION OF THE
BOILER IF THE FAN SHOULD FAIL TO OPERATE.
IT ALSO MAY BE ADVISABLE TO INSTALL AN
AUTOMATIC VENT DAMPER IN THE VENT
SYSTEM TO PREVENT BACKFLOW THROUGH
THE VENT SYSTEM DURING BOILER OFF
CYCLES. SEE FOLLOWING SECTION ON
AUTOMATIC VENT DAMPERS.
IF THE BOILER ROOM MUST BE UNDER A
NEGATIVE PRESSURE AT ANY TIME, AN
INDUCED DRAFT FAN WILL BE REQUIRED.
FURTHER, THE BOILER MUST BE PROVIDED
WITH A "SINGLE ACTING" BAROMETRIC DRAFT
CONTROL - NOT WITH A DRAFT DIVERTER. THE
FAN MUST BE INTERLOCKED WITH THE BOILER
1.8.5 DRAFT CONTROL INSTALLATION - DRAFT DIVERTER
Each atmospheric gas boiler is supplied with a
VERTICAL DRAFT DIVERTER or a BAROMETRIC
DRAFT REGULATOR. THESE DEVICES MUST BE
INSTALLED WITHOUT MODIFICATION. DO NOT
SHORTEN THE COLLAR LENGTH OF A DRAFT
DIVERTER. INSTALL THE BAROMETRIC
DAMPER (IF SUPPLIED) PER INSTRUCTIONS IN
SECTION 1.8.6.
Refer to boiler dimensional for the required distance
from the top of the DRAFT DIVERTER (when
supplied) to the floor. The flue pipe (straight section)
of the diverter must not be shortened or modified in
any manner. The draft diverter must be mounted
directly on top of the boiler as shown in Fig. 1.8.1A.
1.8.6 DRAFT CONTROL INSTALLATION - BAROMETRIC D. R.
FIG. 1.8.6A: BAROMETRIC DRAFT CONTROL
LOCATIONS
FIG. 1.8.6B: BAROMETRIC CONTROL - MG2
BAROMETRIC DRAFT REGULATORS (when supplied)
must be installed such that the minimum distance from
the centerline of the barometric draft control to the top of
the boiler jacket is at least one flue pipe diameter.
Barometric draft controls should preferably be mounted
in the end of a tee as shown in Fig. 1.8.6A. This will allow
better control of minor downdraft conditions.

DO NOT INSTALL A BAROMETRIC DRAFT
CONTROL IN A ROOM SEPARATE FROM THE
BOILER.
The stop and two cover plates are painted in a different
color for easy identification. To remove the stop simply
remove the two screws that hold it to the ring. See Fig.
1.8.6B. To remove cover plates (Item B), bend or break
off the tab that goes through the small hole in the ring.
DO NOT REMOVE THE STOP ATTACHED TO THE
GATE (Item C).
INSTALLATION
Insert the draft control into the collar. The front face of
the control MUST BE PLUMB. The bearing surfaces
MUST BE LEVEL whether the control is on a
horizontal, vertical, or sloping flue pipe. Using a spirit
level, plumb and level accurately. Secure the control in
the collar by tightening the clamping screws. If the
collar is supplied locally, the control may be held in
place by small bolts or sheet metal screws. If the
control has any tendency to sag support it from
overhead.
NOTE: Spill switch provided by others. See wiring
diagram for control point connection.
VERTICAL FLUES
The control is shipped for installation in a vertical flue.
The screw should be left in the top hole of the weight
lever. (Item D)
HORIZONTAL FLUES
For horizontal flues, remove the screw from the upper
hole in the weight lever and insert it in the lower hole.
(Item E)
ADJUSTING THE CONTROL
The control is adjusted to achieve the desired DRAFT
or CO2by adding or removing weights (washer type,
Item F) at the end of the chains. DO NOT MOVE THE
LARGE WEIGHTS ATTACHED DIRECTLY TO THE
GATE (Item G) as they are used only for adjustment at
the factory.
DRAFT should generally be set between -0.02" and -
0.04" w.c. The actual setting must be determined by
taking a CO2reading and a CO reading at the boiler
flue. Reference Table 2.5A for appropriate values.
COMBUSTION READINGS AND DRAFT SETTINGS
MUST BE DONE BY A QUALIFIED BOILER SERVICE
TECHNICIAN.
HIGH DRAFT CONDITIONS
On some installations, because of a high stack, the
draft may be too great to be adjusted using only the
barometric regulator weights. When this occurs, install
a sheet metal baffle through the barometric draft
regulator opening as described in Figure 1.8.6C. The
baffle installation is correct if the gate of the barometric
control is approximately half open while the burner is
operating, and CO2, CO and draft readings are correct.
Barometric
Size (diameter)
Sheet Cut / Form Dimensions
10"
12"
14"
16"
18"
20"
24"
28"
30"
10"
12"
14"
16"
18"
20"
24"
28"
30"
14"
16 3/4"
19 1/2"
22 1/2"
25"
28"
33 1/2"
37"
44"
5"
6"
7"
8"
9"
10"
12"
14"
16"
NOTE THAT THE GATE MUST SWING FREELY
AFTER THE BAFFLE IS INSTALLED.
DO NOT RESTRICT THE BREECHING BETWEEN
THE BAROMETRIC DRAFT CONTROL AND THE
CHIMNEY OR VENT.
CAUTION SHOULD BE USED TO INSURE AGAINST
OVER-RESTRICTING THE FLUE. ALWAYS BE
CERTAIN THAT COMBUSTION IS CORRECT AND A
DRAFT EXISTS AFTER THE BAFFLE IS INSERTED
AND SECURED IN PLACE.
NOTE that the dimension for baffles may vary due to
different types of flue connections and tee sizes.