Bryan Boilers FF1000 User manual
Bryan Steam, LLC www.bryanboilers.com
Free Flex I&O manual Form: 2435
P/N 105641-01 Revision: 11
Date: 10/01/2021
FREE FLEX
CONDENSING BOILER
INSTALLATION & OPERATION MANUAL
AS
ME
H
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:
WA R NING
This manual must only be used by a qualied heating installer/service
technician. Read all instructions in this manual before installing. Perform
steps in the order given. Failure to comply could result in severe
personal injury, death, or substantial property damage.
!
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B. Disclaimers and Local Codes 5
See Figure 1 to Figure
3) 6
A. Receiving the Boiler 10
C. Condensate Trap/Drain Assembly 11
E. Electrical 20
G. Sound Pressure Levels 21
A. Pre-Boil Out Flushing of System 23
B. Boiler Out Procedure 23
E. Boiler Water Treatment 24
B. System Check 26
C. Power the Boiler 26
D. Power the Circulators 26
E. Pressurize the Fuel System 26
F. Boiler Commissioning 26
FF3000) 29
I. Commissioning FF3500 - FF6000 29
A. General Maintenance 31
B. Daily 31
C. Weekly 32
D. Monthly 32
E. Annually 32
G. Burner Assembly Cleaning 32
H. Heat Exchanger Cleaning 33
I. Tube Replacement Procedure 33
3
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Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com
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5
Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com
A. Important Informaon
The following terms are used throughout this
NOTICE.
DANGER
WARNING
CAUTION
or property damage.
NOTICE
B. Disclaimers and Local Codes
must conform to the Standard for Controls and Safety
CSD-1.
personnel refer to those who have completed Bryan
The boiler heat exchanger is manufactured and
stamped in accordance with ASME Boiler and Pressure
NOTICE
Post these instructions and maintain in legible
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C. Test and Inspecons
service personnel. The emissions data and the O2
levels at minimum and maximum input rate can be
which can be referenced in the future by the boiler
are made on each boiler at the factory to ensure it
•
•
•
•
•
DANGER
appliance.
appliance—DO NOT touch any electrical switch or
gas supplier from a remotely located phone. Follow
D. Component Descripon See Figure 1 to Figure 3)
1. Touchscreen display. The display provides
2.
3. Manual gas shutoff valve. The boiler is
one located on the incoming gas supply line
of the main gas valve.
4.
5. Pressure relief valve. The pressure relief
protects the heat exchanger from an over-
6.
Flue gas vent outlet. The boiler comes with
a standard AL 29-4C® stainless steel vent
Located inside the boiler on
FF1500-FF6000)
Settings
Mode Of Operation
Switch
Closed
Switch Open
Minimum 18 13
Maximum 50 45
9. Return water connection. A 3” diameter
provided on the FF3500-6000.
10.
from the heat exchanger. The FF1500-6000 has
a 1” NPT pipe for blow down to clean sediment
from the heat exchanger and a 3” removable
11. Supply water connection. A 3” diameter
is provided on the FF3500-6000.
12. Air vent. The boiler is provided with an internal
dip tube that traps liberated air from the boiler
water. The air vent allows the trapped air to
escape from the boiler.
References 13 to 15 are not used on FF1000
13.
14. Boiler water temperature gauge.
15. Boiler water pressure gauge.
Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com
References 16 to 18 are only used on FF3500 – FF6000
16.
Push Button Display. The display provides
lockout codes.
Temperature Display. Provides for temperature
set points and actual temperature.
14
15
2
13
1
6
3 4
12
5
117
9
10
14
15
2
13
1
6
3 4
12
5
11
7
9
10
Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com
any damage. It is the responsibility of the installer
WARNING
in this manual.
WARNING
skilled installer or service agency must perform
WARNING
This boiler must be properly vented.
This boiler needs fresh air for safe operation
and must be installed so there are provisions for
A. Installaon Conformance
must conform to the Standard for Controls and Safety
CSD-1.
B. Boiler Foundaon
prepared. The boiler should set upon a good level
dimensions of the boiler base. A 4” high housekeeping
pad is suggested.
WARNING
C. Clearance and Serviceability
See Figure 4 and Table 2 for minimum clearances to
the minimum clearances established accordingly.
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.
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Dim Description 1000 1500-
3000
3500-
6000
A Clearance Above Top of Boiler 6” 6” 6”
B Front of 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 construction 16” 23” 23”
ER Right Side – tube access side on
standard construction (FF3500-6000)6” 6” 23”
EC FF1500 -3000 only N/A 23” N/A
Boiler
D
A
B
CV
CH
Flue Gas
Vent
Boiler
EL ER
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10
A. Receiving the Boiler
feet/legs bolted to the skids. These are provided to
with spreader bars to prevent damage to the boiler.
B. Boiler Water and Condensate Connecons
Do not run any pipes along the tube access panel side
of the boiler. Maintain clearances as shown on the
dimensional drawing for servicing of the boiler tubes.
See Figure Figure 4 and Table 2) All piping should be
designed and installed to avoid any loadings on the
1.
a.
are shown on Figure 1. A gate valve should be
installed on the boiler outlet and inlet lines.
This allows the boiler to be isolated from the
2. Safety Relief Valve
a.
relief valve discharge piping must be the
same size as the safety relief valve discharge
opening and run to a point of safe discharge.
the relief valve and the appliance or in the
this can distort valve seats. All piping from the
supported with no weight carried by the
valve.
NOTICE
due to thermal expansion in a closed water supply
system. Contact the water supplier or local plumbing
b.
systems shall be 30 psig. The system shall
c. For systems designed to operate at delta T’s
The system shall operate with no less than
water hammer.
3.
a.
be provided by others in the system piping
separate from the boiler.
4.
a. A drain valve must be installed on the boiler
5.
a. A condensate drain trap is shipped with
the boiler and is provided with a 1” npt
the pH of the condensate should never have
a value lower than 3.5. NO VALVE is to be
installed in this line from the boiler to point
of discharge.
b.
with water as part of your boiler maintenance
schedule to remove any debris that might
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c. A common condensate pump/sump may
be used. Run separate piping from each
condensate drain to the sump. A common
drain may be used to discharge condensate
from the sump. Consult pump/sump materials
individual drain lines should be connected
such that one drain cannot back feed into
pump / sump.
Model Max Condensate Flow (gph)
FF1000 11.2
FF1500 16.8
FF2000 22.4
FF2500 27.9
FF3000 33.5
FF3500 39.1
FF4000 44.7
FF4500 50.3
FF5000 55.8
FF5500 61.4
FF6000 67
d.
of flue gas condensate into public waste
the condensate through a limestone bed.
Consult Bryan Steam or a chemical treatment
CAUTION
Failure to properly pipe the condensate system will
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 size.
C. Condensate Trap/Drain Assembly
1.
Installed to the outlet in the rear of the boiler.
a. Mount as shown in Figure 5 and Figure 6
Outlet of the vent is to be level).
b. Insert wires through grommet on back panel
and plug in the two wires into the bullet plugs
inside the back of the boiler.
2. A condensate drain trap assembly is included
and must be installed to the outlet in the rear
of the appliance.
a.
escaping into the boiler room.
b.
the event the drainage of the condensate is
blocked.
Float Switch
1" PVC Union
Flue Gas Trap
Vent
Outlet (1" Socket Connection)
Cleanout Port
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E. Combuson Air Supply System
boiler room with appropriate openings for fresh air
supply. Temporary air intakes such as windows and
doors should be avoided since they may be closed.
AVOIDED AT ALL COSTS! Provisions should be made
personnel comfort.
dampers are closed.
obstructed in any manner.
WARNING
).
with local and/or State codes or the authority having
to the boiler room shall be provided as follows:
WARNING
Combustion air provided solely from an indoor
source is discouraged. No dimension for a round or
rectangular opening shall be less than 3”.
D. Gas Supply Connecons
The installation must conform completely to the
and applicable regional regulations for the class;
which should be followed carefully in all cases.
1. Drip Leg
a.
with the gas train. The gas line must be
connected to a supply main at least as large
that the boiler gas train components and
burner may be easily removed for service.
2. Gas Piping Leak Test
a.
Leaks shall be checked using a soap and water
gas valve shall be checked. A pressure
gauge shall be installed down stream of the
main motorized gas valve and up stream of
stream of the main motorized gas valve shall
be tested for leaks.
3.
a. gas valve
b. The high and low gas pressure switches
and limits the escape of gas less than 1.0
diaphragm ruptures.
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1. Two Permanent Opening Method
a.
be provided. The openings shall be open
directly to the outside or ducted directly to
the outside.
b. When directly open to the outside or ducted
or duct shall have a minimum free open area
of 1 in
c. If ducted to the outside through horizontal
minimum free area of 1 in
2. One Permanent Opening Method
a. One opening commencing within 12” of
the top of the room shall be provided. The
opening shall be directly to the outside
or shall be ducted to the outside with a
b. The opening or duct shall have a minimum
free area of:
c. 1 in
boilers) in the room.
d.
3. Mechanical Air Supply Systems
a.
/min.
for every 1000 Btu/hr input for all appliances
located in the space.
b.
be provided 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
d. If the combustion air is provided by a
4. Louvers and Grilles
a.
the net free area of each opening. Where the
assumed that wood louvers have a 25 percent
percent free area. Non-motorized louvers
5. Screens
a. Screens shall not be smaller than 1/4" mesh.
6. Motorized Louvers
a. Motorized louvers shall be interlocked with
the appliance so they are proven in the full
shall be provided to prevent the main burner
during burner startup and to shut down the
main burner if the louver closes during burner
a.
following:
b. Ducts shall be constructed of galvanized steel
c. Ducts shall terminate in an unobstructed
air to the appliances.
d. Ducts shall serve a single space.
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14
e. Ducts shall not serve both upper and lower
air openings shall be maintained to the source
f.
g.
not slope downward toward the source of
h.
codes that address the amount of air and/or
air.
i.
k.
l.
WARNING
chemicals are present. Severe boiler corrosion and
failure will result.
a.
constructed of galvanized steel or a material
strength and rigidity.
b. Appendix B shall be used to determine the
arrangements see Appendix D.
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system manufacturer.
A. General Venng
1. The venting system shall be designed and
applicable local building codes to develop a
gasses to the outdoors.
2.
3. Consult the vent pipe manufacturer’s
instructions for vent system assembly and
4. Vent pipe system shall be acceptable for use
with boiler fuel type.
5.
a. This boiler is shipped with an AL 29-4C® Heat-
b.
prohibited.
6.
Other materials may be used that meet the
a. Flue system material shall be capable of
b. Flue system material shall have the same
as AL29-4C.
c.
Do not reduce the diameter of the vent pipe.
The vent pipe must not be smaller than the
vent connector on the boiler.
completed vent system must be rigid and able
to withstand impacts without collapse.
9.
10. Vent pipe system must be fully sealed.
11.
12. Appendix B shall be used to determine the vent
13. It is permissible to run vent pipe through a
clearances to combustible materials are
maintained.
14. The minimum clearance to combustible
15.
follows:
a.
over public walkway where local experience
boiler creates a nuisance or hazard.
b.
c.
window or gravity air inlet.
d.
relief valves. This distance may be reduced if
etc.
16.
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16
must close the opening between the vent pipe
and the structure.
Enclose vent passing through occupied or
unoccupied spaces above the boiler with
materials having a fire resistance rating at
or ceiling. Maintain minimum clearance to
19.
if used
foot horizontally.
20.
collar to prevent moisture from entering the
structure.
21.
22.
23.
24. For instances where the vent system
manufacturer’s instructions do not make a
a. Make sure pipe and fittings are clean by
4500 or 6500 or seal vent pipe.
b. Refer to the appropriate drawings in Appendix
D of this manual to determine common
WARNING
CO
WARNING
Do not use a barometric damper with this boiler.
into the boiler room.
B. Category II Venng
Category II venting is an engineered system and
and “APPROVED” by the local authority. The boiler
manufacturer takes no responsibility for vent systems
to the following.
1.
gases 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
of the boiler.
4.
5. Vertical venting is recommended. Other
acceptable if proven by the vent manufacturers
6.
from the boiler room. Follow the guidelines
in this manual. Other arrangements may be
acceptable if proven by the vent manufacturers
It is recommended that a Carbon Monoxide
detector be installed and interlocked to the
Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com
Boiler
Model
Flue gas
ow, ACFM
@40% XSA
200°F
Comb. air
req. SCFM
@40% XSA
0°F
Flue Size
FF 1000 301 220 6”
FF 1500 452 330 8”
FF 2000 603 441 8”
FF 2500 753 550 10”
FF 3000 904 661 10”
FF 3500 1055 771 12”
FF 4000 1206 881 12”
FF 4500 1357 991 14”
FF 5000 1507 1101 14”
FF 5500 1658 1212 14”
FF 6000 1809 1322 14”
WARNING
C. Massachuses
For all side wall horizontally vented gas fueled
Commonwealth and where the side wall exhaust
1. INSTALLATION OF CARBON MONOXIDE
a hard wired carbon monoxide detector with
or hard wire carbon monoxide detector with
the side wall horizontal vented gas fueled
the property owner to secure the service
detectors.
a. In the event that the side wall horizontally
b.
operated carbon monoxide detector with an
alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS.
3.
shall be permanently mounted to the exterior
feet above grade directly in line with the exhaust
vent terminal for the horizontally vented gas
Bryan Steam LLC, 783 N Chili Ave, Peru, IN 46970 Web: www.bryanboilers.com
4. INSPECTION. The state or local gas inspector
of the side wall horizontally vented gas fueled
observes carbon monoxide detectors and
signage installed in accordance with the
a.
i.
adopted by the Board; and
ii. Product Approved side wall horizontally
building or structure used in whole or in
b.
When the manufacturer of Product Approved
system shall include:
i.
system components; and
ii. A complete parts list for the vent system
c.
PROVIDED. When the manufacturer of a
Product Approved side wall horizontally
the manufacturer:
i.
instructions shall be included with the
ii. The “special venting systems” shall be
a parts list and detailed installation
d.
Product Approved side wall horizontally
instructions shall remain with appliance
D. Venng Requirements for Canada
or a combination of appliances has a total input
1.
CSA-B149.1-05 for Appliances having an input
exceeding 400 MBH:
a.
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
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b.
area of not less than 1 in
for each kW) of the total
openings for ventilation air. Please refer
c. When an air supply duct is used to supply
located where there is no possibility of cold
2.
Grilles
a.
or screens from the gross area of the opening.
b.
6
).
c. No manually operated damper or manually
d. A motorized damper or louvers shall be
unless the damper or louver is in the fully
3.
a. When combustion air is supplied by
shall be installed and wired into the safety
limit circuit of the primary safety control to
failure.
4.
a.
systems as previously described.
NOTICE
Please note that the information provided in
of all system designs must be acceptable to the
i.
of the listed appliance. This boiler is a
ii.
manual.
iii.
iv.
system serving any other appliance. This
v.
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20
E. Electrical
WARNING
All electrical connections must conform to the
CSA C22.1 Electrical Code and all other State and
Local codes.
A separate electrical circuit must be run from
the main electrical service with an over-current
device/disconnect in the circuit. A service switch is
to danger in the event of an emergency. See Table 5
for available voltages.
FF1000
Voltage FLA CCA MHP MA
120/1/60 6.6 2.6 .46 4
FF1500
Voltage FLA CCA MHP MA
120/1/60 13.1 2.6 1.1 10.5
208-240/1/60 6.9 2.6 1.1 4.3
FF2000 to FF3000
Voltage FLA CCA MHP MA
120/1/60 15.6 2.6 1.5 13
208-240/1/60 8.3 2.6 1.5 5.7
208-240/3/60 9.5 2.6 3 6.9
480/3/60 5.25 1.25 3.2 4
FF3500 to FF4000
Voltage FLA CCA MHP MA
208-240/3/60 10.5 2.6 3 6.9
480/3/60 5.25 1.25 3.2 4
FF4500 to FF6000
Voltage FLA CCA MHP MA
208-240/3/60 26 2.6 10.7 24
480/3/60 14.25 1.25 10.7 13
FLA = Full Load Amps : CCA = Control Circuit Amps
: MHP = Motor Horse Power : MA = Motor Amps
proper terminals provided in boiler electrical cabinet.
Refer to wiring diagram supplied with boiler for wiring
See Appendix H for sample-wiring diagrams. An
as-built wiring diagram is included with every boiler
) for
F. Gas Supply Requirements
Refer to Table 6 for minimum and maximum gas
supply pressure. When the gas supply pressure
supply pressure. For proper gas supply sizing refer
to Table 20.
NOTICE
The step down regulator shall be installed at least
60 pipe diameters from the boiler gas inlet manual
shutoff valve and vented to atmosphere. Vent
Limiters are NOT acceptable. This will ensure proper
Model Capacity Inlet
(npt)
Min.
(iwc)
Max.
(iwc)
FF1000 1000 1 4 14
FF1500 1500 2 4 14
FF2000 2000 2 4 14
FF2500 2500 2 4 14
FF3000 3000 2 4 14
FF3500 3500 2 7 14
FF4000 4000 2 7 14
FF4500 4500 2 7 14
FF5000 5000 2 7 14
FF5500 5500 2 7 14
FF6000 6000 2 7 14
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