Bryan Boilers FF1000 User manual

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: [phone] Fax: [phone] Email: [e-mail]
i
FREE FLEX
High Efficiency, Low Emission
CONDENSING BOILER
INSTALLATION & OPERATION MANUAL
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:

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: [phone] Fax: [phone] Email: [e-mail]
ii
Table of Contents
1Introduction........................................................................................................................................................................6
1.1 Important Information .........................................................................................................................................6
1.2 Disclaimers and Local Codes..............................................................................................................................6
1.3 Test and Inspections..............................................................................................................................................7
1.4 Component Description .......................................................................................................................................8
2Pre-Installation............................................................................................................................................................... 10
2.1 Installation Conformance ................................................................................................................................. 10
2.2 Boiler Foundation................................................................................................................................................ 10
2.3 Clearances and Serviceability ......................................................................................................................... 10
3Installation ....................................................................................................................................................................... 12
3.1 Receiving The Boiler........................................................................................................................................... 12
3.2 Boiler Connections .............................................................................................................................................. 12
3.2.1 Flow Connection..........................................................................................................................................12
3.2.2 Safety Relief Valves..................................................................................................................................... 12
3.2.3 Minimum Relief Valve Settings.............................................................................................................. 12
3.2.4 Expansion Tank Connections ................................................................................................................. 12
3.2.5 Drain Connection......................................................................................................................................... 12
3.2.6 Condensate Drain Connection ............................................................................................................... 13
3.2.6.1 FF1000 Condensate Drain Trap ...................................................................................................13
3.2.6.2 FF1500 – 3000 Condensate Drain Trap.................................................................................... 13
3.2.7 Gas Supply Connection.............................................................................................................................. 14
3.2.7.1 Drip Leg .................................................................................................................................................. 14
3.2.7.2 Gas Piping Leak Test ......................................................................................................................... 14
3.2.7.3 Venting of Gas Train Components............................................................................................... 14
3.3 Combustion Air Supply System...................................................................................................................... 14
3.3.1 Combustion Air Openings:....................................................................................................................... 15
3.3.1.1 Two Permanent Opening Method................................................................................................ 15
3.3.1.2 One Permanent Opening Method ................................................................................................ 15
3.3.1.3 Mechanical Air Supply Systems.................................................................................................... 15
3.3.2 Louvers, Grilles, and Screens.................................................................................................................. 16
3.3.2.1 Louvers and Grilles:........................................................................................................................... 16
3.3.2.2 Screens.................................................................................................................................................... 16
3.3.2.3 Motorized Louvers:............................................................................................................................ 16
3.3.2.4 Combustion Air Ducts....................................................................................................................... 16
3.3.3 Ducted Combustion Air............................................................................................................................. 17
3.4 Venting Requirements ....................................................................................................................................... 17
3.4.1 Category II Venting..................................................................................................................................... 19
3.4.2 Massachusetts............................................................................................................................................... 20
3.4.3 Combustion Air and Venting Requirements for Canada............................................................. 21
3.4.3.1 Air Supply Requirements per CAN/CSA-B149.1-05 for Appliances having an input
exceeding 400 MBH................................................................................................................................................. 21
3.4.3.2 Combustion Air Supply Dampers, Louvers, and Grilles......................................................22
3.4.3.3 Mechanical Combustion Air Supply............................................................................................ 22
3.4.3.4 Appliance Venting per CAN/CSA-B149.1-05 .......................................................................... 22
3.5 Requirements ........................................................................................................................................................ 23
3.5.1 Electrical ......................................................................................................................................................... 23
3.5.2 Gas Supply Requirements........................................................................................................................ 24
3.5.3 Sound Pressure Levels ..............................................................................................................................24

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: [phone] Fax: [phone] Email: [e-mail]
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
4SYSTEM 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
5Service, 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

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: [phone] Fax: [phone] Email: [e-mail]
iv
Appendix F.1 Single Boiler, Primary / Secondary ............................................................................................... 56
Appendix F.2 Multiple Boilers, Primary Reverse-Return Piping...................................................................57
Appendix F.3 Multiple Boilers, Primary / Secondary Reverse Return Piping ......................................... 58
Appendix F.4 Multiple Boilers, Primary / Secondary Piping ..........................................................................59
Appendix F.5 Multiple Boilers, Primary / Secondary Piping, Heating with Domestic Hot Water...60
Appendix F.6 Multiple Boilers, Primary / Secondary Piping, Heating with Domestic Hot Water
(continued) .......................................................................................................................................................................... 61
Appendix G Water Flow Pressure Drops .....................................................................................................................62
Appendix H Wiring Diagrams........................................................................................................................................... 63
Appendix H.1 FF1000 Wiring Diagram.................................................................................................................... 63
Appendix H.2 FF1500 To FF3000 115 VAC Single Phase Wiring Diagram............................................... 65
Appendix H.3 FF1500 To FF3000 208 – 230 VAC Single Phase Wiring Diagram ..................................66
Appendix H.4 FF2000 To FF3000 208-460 VAC Three Phase Wiring Diagram......................................68
Appendix I Repair Parts...................................................................................................................................................... 70
Appendix I.1 FF1000 Heat Exchanger...................................................................................................................... 70
Appendix I.2 FF1000 Burner Assembly...................................................................................................................72
Appendix I.3 Gas Train and Upper Vestibule Controls ...................................................................................... 73
Appendix I.4 Jacket........................................................................................................................................................... 75
Appendix I.5 Outlet Manifold ....................................................................................................................................... 77
Appendix I.6 Miscellaneous External Components............................................................................................. 79
Appendix I.7 Controls...................................................................................................................................................... 81
Tables
Table 1Water Flow Switch Settings.................................................................................................................8
Table 2: Clearances and Serviceability ..........................................................................................................11
Table 3: Typical Condensate Flow Rate .......................................................................................................13
Table 4: Combustion Air and Flue Gas Requirements ..............................................................................19
Table 5: Electrical Requirements...................................................................................................................23
Table 6: Gas Supply Requirements ...............................................................................................................24
Table 7 Sound Pressure Levels ......................................................................................................................24
Table 8 Minimum Water Flow Rates for Variable Primary Pumping......................................................25
Table 9 Maximum Water Flow Rates for Variable Primary Pumping .....................................................25
Table 10 Water Flow Rates for Primary / Secondary Pumping 20F ΔT ................................................26
Table 11 Water Flow Rates for Primary / Secondary Pumping 40F ΔT ................................................26
Table 12 GPM Increase for Glycol Systems................................................................................................27
Table 13: Chemical Agents and Effects........................................................................................................29
Table 14 Recommended Feed Water Limits ...............................................................................................30
Table 15: Safety Device Test..........................................................................................................................35
Table 16: Safety and Operating Controls .....................................................................................................44
Table 17: General Troubleshooting ..............................................................................................................45
Table 18: Maximum Gas Capacity Of Schedule 40 Pipe ...........................................................................48
Table 19: Equivalent Lengths Of Standard Pipe Fittings And Valves.....................................................49
Table 20: Specific Gravity Correction Factors ............................................................................................49
Table 21: Heat Exchanger Parts ....................................................................................................................71
Table 22: Burner Assembly ............................................................................................................................72
Table 23: Gas Train and Upper Vestibule Controls...................................................................................74
Table 24: Jacket ................................................................................................................................................76

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: [phone] Fax: [phone] Email: [e-mail]
v
Table 25: Outlet Manifold ..............................................................................................................................78
Table 26: Miscellaneous External Components..........................................................................................80
Table 27: Controls ...........................................................................................................................................82
Figures
Figure 1: FF1000 External Boiler Connections and Components.............................................................9
Figure 2: FF1500 - 3000 External Boiler Connections and Components.................................................9
Figure 3: Clearances and Serviceability.........................................................................................................11
Figure 4: FF 1000 Condensate Drain Trap..................................................................................................13
Figure 5: FF1500 - 3000 Condensate Drain Trap.......................................................................................14
Figure 6: High Fire Adjustment on the Main Gas Valve Regulator.........................................................33
Figure 7: Ignition Assembly ...........................................................................................................................39
Figure 8: Panel Removal in Preparation for Tube Inspection ..................................................................41
Figure 9: Tube Puller Insertion......................................................................................................................42

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: [phone] Fax: [phone] Email: [e-mail]
6
1Introduction
1.1 Important Information
The following terms are used throughout this
manual to bring attention to the presence of
hazards of various risk levels, or to important
information concerning product life. It is
critical that all personnel read and follow all
the information provided in the boxes marked
DANGER, WARNING, CAUTION, and
NOTICE.
DANGER
Indicates an imminently hazardous
situation, which, if not avoided, will result
in death, serious injury or substantial
property damage .
WARNING
Indicates a potentially hazardous
situation, which, if not avoided, could
result in death, serious injury or
substantial property damage.
CAUTION
Indicates a potentially hazardous
situation, which, if not avoided, may result
in moderate or minor injury or property
damage.
NOTICE
Indicates specific instructions on
installation, operation, or maintenance,
which are important but not related to
personal injury hazards.
1.2 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 Safety Devices for Automatically
Fired Boilers, ANSI/ ASME CSD-1.
Installation, start-up, and maintenance of this
equipment can be hazardous and requires
trained, qualified installers and service
personnel. Do not install, operate, service or
repair any components of this equipment
unless you are qualified and fully understand
all requirements and procedures. Trained
personnel refer to those who have completed
Bryan Steam Service School training specific
to this product.
The boiler heat exchanger is manufactured
and stamped in accordance with ASME Boiler
and Pressure Vessel Code, Section IV for a
maximum allowable working pressure and
operating temperature of 160 psig (1103 kPa)
and 210 F(99 C) respectively. Aqua-stat is
factory set at 200 F (93 C).
NOTICE
Post these instructions and maintain in
legible condition.

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: [phone] Fax: [phone] Email: [e-mail]
7
1.3 Test and Inspections
Upon the completion of boiler installation,
final air-fuel adjustments are to be made by
factory trained service personnel. The
emissions data and the O2 levels at minimum
and maximum input rate can be found on the
back side of the front-boiler’s door, which can
be referenced in the future by the boiler
operator(s) when troubleshooting and
servicing the boiler. In addition, the following
tests and inspections are made on each boiler
at the factory to ensure it meets our highest
safety and functionality standards.
ASME hydrostatic test inspection
Electrical components inspection
Operating & efficiency test
Final engineering inspection
Crating inspection
Danger
DO NOT store or use gasoline or other
flammable vapors or liquids in the vicinity
of this or any other appliance.
If you smell gas vapors, DO NOT try to
operate any appliance—DO NOT touch
any electrical switch or use any phone in
the building. Immediately, call the gas
supplier from a remotely located phone.
Follow the gas supplier’s instructions or if
the supplier is unavailable, contact the fire
department.

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: [phone] Fax: [phone] Email: [e-mail]
8
1.4 Component Description
1. Touchscreen display. The display
provides easy access for viewing and
adjusting boiler operational parameters,
monitoring historical performance
characteristics and annunciating boiler
alarm/lockout conditions.
2. Boiler On/Off switch.
3. Manual gas shutoff valve. The boiler is
equipped with two manual gas shut off
valves, one located on the incoming gas
supply line outside of the boiler, and the
other downstream of the main gas valve.
4. Main gas supply connection.
5. Pressure relief valve. The pressure relief
protects the heat exchanger from an over-
pressure condition.
6. Ducted combustion air flange.
7. Flue gas vent outlet. The boiler comes
with a standard AL 29-4C® stainless steel
vent connection.
8. Boiler water flow switch. The boiler
water flow switch is adjustable within the
parameters listed in Table 1.
Settings
Mode Of Operation
Switch
Closed
Switch
Open
Minimum 18
13
Maximum 50
45
Table 1Water Flow Switch Settings
9. Return water connection. A 3” diameter
Victaulic grooved connection is provided
on the FF1000. A 3”, 150# class, flange
is provide on the FF1500 – 3000.
10. Cleanout and inspection. A 3” diameter
Victaulic grooved connection is provided
for inspecting and cleaning sediment from
the heat exchanger.
11. Supply water connection. A 3” diameter
Victaulic grooved connection is provided
on the FF1000. A 3”, 150# class, flange
is provide on the FF1500 – 3000.
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.
13. Boiler reset push button.
14. Boiler water temperature gauge.
15. Boiler water pressure gauge.

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: [phone] Fax: [phone] Email: [e-mail]
9
Figure 1: FF1000 External Boiler
Connections and Components
Figure 2: FF1500 - 3000 External Boiler
Connections and Components

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: [phone] Fax: [phone] Email: [e-mail]
10
2Pre-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.
WARNING
This boiler needs fresh air for safe
operation and must be installed so there
are provisions for adequate combustion
and ventilation air.
2.1 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.
2.2 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.
2.3 Clearances and Serviceability
See Figure 3 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.

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: [phone] Fax: [phone] Email: [e-mail]
11
Figure 3: Clearances and Serviceability
Dim
Description
1000
1500-3000
A
Clearance
Above Top of
Boiler
6” 6”
B
Front of Boiler
– Burner End
24” 25-5/8”
CH
From Chimney
or Vent
Collector
measured
horizontally
18” 18”
Dim
Description
1000
1500-3000
CV
From Chimney
or Vent
Collector
measured
vertically
18” 18”
D
Rear of Boiler -
opposite burner
end
6” 6”
EL
Left Side – tube
access side on
standard
construction
16” 23”
ER
Right Side
6”
6”
Table 2: Clearances and Serviceability
Boiler
D
A
B
CV
CH
Flue Gas
Vent
Boiler
EL ER

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: [phone] Fax: [phone] Email: [e-mail]
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3Installation
3.1 Receiving The Boiler
The boiler is shipped from the factory with
(4) shipping feet/legs bolted to the skids.
These are provided to facilitate unloading
/moving with a forklift. Lifting points are
also provided to enable over-head lifting with
spreader bars to prevent damage to the boiler.
The shipping feet/legs MUST BE
REMOVED after the boiler is set in-place on
its concrete foundation before any
piping/electrical connections are made. It is
recommended that the plastic protective
cover be left on as long as possible to reduce
finish damage from the installation.
3.2 Boiler Connections
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. All piping
should be designed and installed to avoid any
loadings on the boiler connections or piping.
3.2.1 Flow Connection
The system supply and return flow
connections 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 heating system for draining
and servicing.
3.2.2 Safety Relief Valves
Safety relief valve(s) are shipped loose.
Connections are provided in the top of the
boiler for the safety relief valve(s). The safety
relief valve discharge piping must be the same
size as the safety relief valve discharge
opening and run to a point of safe discharge.
No shutoff valves are to be placed between
the relief valve and the appliance or in the
discharge piping. Avoid over-tightening as
this can distort valve seats. All piping from
the 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. Contact the
water supplier or local plumbing inspector
on how to correct this situation. DO NOT
PLUG THIS RELIEF VALVE.
3.2.3 Minimum Relief Valve Settings
The minimum relief valve setting for standard
systems shall be 30 psig. The system shall
operate with no less than 26 psig at all times.
For systems designed to operate at delta T’s
greater than 40°F, the boiler shall be equipped
with a minimum relief valve setting of 60 psig.
The system shall operate with no less than 50
psig at all times. This will prevent boiler
water hammer.
3.2.4 Expansion Tank Connections
Connection(s) to an expansion tank are to be
provided by others in the system piping
separate from the boiler.
3.2.5 Drain Connection
A drain valve must be installed on the boiler
drain connection, the same pipe size as this
connection, to allow draining of the boiler.

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: [phone] Fax: [phone] Email: [e-mail]
13
3.2.6 Condensate Drain Connection
A condensate drain trap is shipped with the
boiler and is provided with a 1” nps
connection to drain the condensed products
of combustion from the boiler. Pipe with
continuous Teflon, high temperature silicone
tubing, or other tubing material compatible
with flue gas condensate. The condensate
temperature should never exceed 212o F and
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.
The condensate drain trap should be flushed
with water as part of your boiler maintenance
schedule to remove any debris that might
have accumulated over time.
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 of construction. If a common sump
is used, individual drain lines should be
connected such that one drain cannot back
feed into another drain. Use Table 3 for
sizing the pump / sump.
Table 3: Typical Condensate Flow Rate
Model
Max Condensate Flow (gph)
FF1000
7
FF1500
10.5
FF2000
16
FF2500
21.5
FF3000
27
Consult local authorities regarding disposal of
flue gas condensate into public waste water
system. Some jurisdictions require that
condensate be buffered before discharge. This
buffering is commonly achieved by draining
the condensate through a limestone bed.
Consult Bryan Steam 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 size.
3.2.6.1 FF1000 Condensate Drain Trap
Ensure that the condensate drain trap is filled
with water prior to running the boiler to
prevent flue gas emission to the boiler room.
It is recommended that the personnel
responsible for running and maintaining the
boiler periodically check the water level in the
condensate drain trap bend, especially, when
the boiler is operating in a non-condensing
condition for an extended period of time.
Figure 4: FF 1000 Condensate Drain Trap
1. Union Connection to the boiler
condensate drain line
2. Removable cleaning plug
3. Condensate drain outlet connection
3.2.6.2 FF1500 – 3000 Condensate Drain
Trap

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: [phone] Fax: [phone] Email: [e-mail]
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Figure 5: FF1500 - 3000 Condensate Drain
Trap
1. 1” npt outlet connection
2. Trap vent connection (tubing not shown
for clarity)
3. 2” threaded cleanout
4. Float ball
3.2.7 Gas Supply Connection
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 propane installation code
(CAN/CSA B149.1-05), and applicable
regional regulations for the class; which
should be followed carefully in all cases.
Authorities having jurisdiction should be
consulted before installations are made. Refer
to paragraph 3.5.2 for gas supply
requirements.
3.2.7.1 Drip Leg
A drip leg, or sediment trap, is supplied with
the gas train. 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.
3.2.7.2 Gas Piping Leak Test
After completion of the gas-piping hookup,
the installation must be checked for leaks.
Leaks shall be checked using a soap and water
solution. All joints up to the main motorized
gas valve shall be checked. A pressure gauge
shall be installed down stream of the main
motorized gas valve and up stream of the
manual gas shutoff valve in the closed
position to ensure the main motorized valves
are not leaking by. During commissioning,
the remainder of the gas train joints down
stream of the main motorized gas valve shall
be tested for leaks.
3.2.7.3 Venting of Gas Train Components
The MBC (gas valve) has an internal, factory
installed vent limiter re ANSI Z21.18/ CSA
6.3. Venting required unless otherwise
accepted by the authority having jurisdiction.
The high and low gas pressure switches
incorporate a vent limiter as per UL 353 and
limits the escape of gas less than 1.0 CFH of
natural gas at 7 PSI if internal switch
diaphragm ruptures.
3.3 Combustion Air Supply System
For proper combustion it is necessary to
provide the 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. In addition
to air needed for combustion, sufficient air
must be supplied for ventilation as well as
other air consuming equipment that may be
present in the boiler room. Often when
personnel are working in the boiler room,
combustion air openings are closed due to the
temperature of the outside air. THIS MUST
BE AVOIDED AT ALL COSTS! Provisions
should be made to heat the outside
combustion air, if necessary, for personnel
comfort.

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: [phone] Fax: [phone] Email: [e-mail]
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Positive means for supplying an ample
amount of outside air, allowing for the
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).
3.3.1 Combustion Air Openings:
The design of combustion air openings
MUST comply with local and/or State codes
or the authority having jurisdiction. As a
minimum, combustion air openings to the
boiler room shall be provided as follows:
NOTICE
Combustion air provided solely from an
indoor source is discouraged. No
dimension for a round or rectangular
opening shall be less than 3”.
3.3.1.1 Two Permanent Opening Method
One opening starting within 12” of the top of
the boiler room and one starting within 12” of
the bottom of the boiler room shall be
provided. The openings shall be open directly
to the outside or ducted directly to the
outside.
When directly open to the outside or ducted
to the outside by vertical ducts, each opening
or duct shall have a minimum fee open area
of 1 in2per 4000 BTU total input rating of the
boiler(s) in the room.
If ducted to the outside through horizontal
ducts, each opening or duct shall have a
minimum free area of 1 in2per 2000 BTU
total input rating of the boiler(s) in the room.
3.3.1.2 One Permanent Opening Method
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
horizontal or vertical duct.
The opening or duct shall have a minimum
free area of:
1 in2/ 3000 BTU /hour of the total input
ratting of all appliances (boilers) in the room.
Additional area must be provided for other air
consuming equipment in the room.
3.3.1.3 Mechanical Air Supply Systems
The combustion air supply may be provided
by a mechanical air supply system. If utilized,
the combustion air must be provided from
the outside at a minimum rate of 0.35 ft3/min.
for every 1000 Btu/hr. input for all appliances
located in the space.

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: [phone] Fax: [phone] Email: [e-mail]
16
If exhaust fans are utilized, additional air shall
be provided to replace the exhausted air.
Each boiler and other appliance must be
interlocked to prevent operation when the
mechanical air supply system is not in
operation.
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.
3.3.2 Louvers, Grilles, and Screens
3.3.2.1 Louvers and Grilles:
The required size of openings for
combustion, ventilation, and dilution air shall
e based on the net free area of each opening.
Where the free area through a design of
louver, grille, or screen is know, it shall be
used in calculating the size opening required
to provide the free area specified. Where the
louver and grille design and free area are not
know, it shall be assumed that wood louvers
have a 25 percent free area, and met louvers
and grilles have 75 percent free area. Non-
motorized louvers and grilles shall be fixed in
the open position.
3.3.2.2 Screens
Minimum Screen Mesh Size:
Screens shall not be smaller than 1/4 “ mesh.
3.3.2.3 Motorized Louvers:
Motorized louvers shall be interlocked with
the appliance so they are proven in the full
open position prior to main burner ignition
and during main burner operation. Means
shall be provided to prevent the main burner
from igniting should the louver fail to opening
during burner startup and to shut down the
main burner if the louver close during burner
operation.
3.3.2.4 Combustion Air Ducts
Combustion air ducts shall comply with the
following:
Ducts shall be constructed of galvanized steel
or a material having equivalent corrosion
resistance, strength and rigidity.
Ducts shall terminate in an unobstructed
space, allowing free movement of combustion
air to the appliances.
Ducts shall serve a single space.
Ducts shall not serve both upper and lower
combustion air openings where both such
openings are used. The separation between
ducts serving the upper and lower combustion
air openings shall be maintained to the source
of combustion air.
Ducts shall not be screened where terminating
in an attic space.
Horizontal upper combustion air ducts shall
not slope downward toward the source of
combustion air.
For informational purposes, there are several
codes that address the amount of air and/or
size of the opening(s) in walls for combustion
air.

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: [phone] Fax: [phone] Email: [e-mail]
17
NFPA 54, National Fuel Gas Code (ANSI
Z223.1)
ASME CSD-1, Controls and Safety Devices
for Automatically Fired Boilers
ASME Section VI, Recommended Rules for
Care and Operation of Heating Boilers
BOCA, National Mechanical Code
WARNING:
Do not locate air intakes where petroleum
distillates, CFC’s, detergents, volatile
vapors or any other chemicals are present.
Severe boiler corrosion and failure will
result.
3.3.3 Ducted Combustion Air
Ducted combustion air can be connected to
the boiler air intake flange. Ducts shall be
constructed of galvanized steel or a material
having equivalent corrosion resistance,
strength and rigidity.
Appendix B shall be used to determine the
ducted combustion air system equivalent
length. For typical ducted combustion air
arrangements see Appendix E.
3.4 Venting Requirements
In order to properly vent this boiler, the
installer must select and install a venting
system that meets all requirements specified in
this section, as well as following the
instructions provided by the venting system
manufacturer.
1. The venting system shall be designed and
constructed in accordance with the
National Fuel Gas Code, NFPA 54 /
ANSI Z223.1 and applicable local building
codes to develop a positive flow adequate
to convey flue or vent gasses to the
outdoors.
2. If this boiler is being installed in
Massachusetts, follow the Massachusetts
Code Instructions printed later in this
section.
3. Consult the vent pipe manufacturer’s
instructions for vent system assembly and
system specific installation requirements.
4. Vent pipe system shall be acceptable for
use with boiler fuel type.
5. Vent pipe system shall be compatible
either by directly connecting, or by using
an adaptor, to the boiler vent connection.
a. This boiler is shipped with an AL 29-
4C®Heat-Fab Saf-T-Vent connection.
b. Alteration of the boiler vent
connection is prohibited.
6. Recommended flue system material is
AL29-4C. Other materials may be used
that meet the following requirements:
a. Flue system material shall be capable
of continuous operation at 230°F or
higher. 
b. Flue system material shall have the
same corrosion resistance to flue 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.
7. Do not reduce the diameter of the vent
pipe. The vent pipe must not be smaller
than the vent connector on the boiler.
8. Vent pipe system must be adequately
supported at intervals no less than five (5)
feet apart. The completed vent system
must be rigid and able to withstand
impacts without collapse.

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: [phone] Fax: [phone] Email: [e-mail]
18
9. The boiler’s venting is Category IV
(positive vent pressure, flue condensing),
with regards to the National Fuel Gas
Code, NFPA 54 / ANSI Z223.1.
10. Vent pipe system must be fully sealed.
11. Atmospheric venting is prohibited.
12. Appendix B shall be used to determine
the vent system equivalent length.
13. It is permissible to run vent pipe through
a vertical or horizontal chase provided
minimum clearances to combustible
materials are maintained.
14. The minimum clearance to combustible
material is six (6) inches unless otherwise
specified by the manufacturer.
15. The vent termination location is restricted
as follows:
a. Minimum twelve (12) inches above
grade plus normally expected snow
accumulation or seven (7) feet above
grade if located adjacent to public
walkways. DO NOT INSTALL over
public walkway where local experience
indicates condensation or vapor from
the boiler creates a nuisance or hazard.
b. Minimum three (3) feet above any
forced air inlet located within ten (10)
feet of the vent termination.
c. Minimum four (4) feet below, four (4)
feet horizontally or one (1) foot above
any door, window or gravity air inlet.
d. Minimum four (4) feet horizontally
from electric meters, gas meters,
regulators and relief valves. This
distance may be reduced if equipment
is protected from damage due to
condensate or vapor by enclosure,
overhangs, etc.
16. Use appropriately designed thimbles when
passing through combustible walls or
roofs.
17. Install fire-stops where vent passes
through floors, ceilings or framed walls.
The fire-stop must close the opening
between the vent pipe and the structure.
18. Enclose vent passing through occupied or
unoccupied spaces above the boiler with
materials having a fire resistance rating at
least equal to the rating of the adjoining
floor or ceiling. Maintain minimum
clearance to combustible materials.
19. Locate vent terminal above combustion
air intake terminal (if used) and no closer
than (1) foot horizontally.
20. Vertical venting requires flashing and a
storm collar to prevent moisture from
entering the structure.
21. Vertical vent termination must be at least
two (2) feet plus the expected snow
accumulation above roof penetration
height.
22. This boiler has been certified with AL29-
4C®venting. Select a vent material that is
approved for use with condensing flue
gasses.
23. Install vent system before installing air
intake, water, gas or electrical connections.
24. For instances where the vent system
manufacturer’s instructions do not make a
specification, refer to the below points.
a. Make sure pipe and fittings are clean
by swabbing with alcohol. Use Dow
Corning 736 or 732 RTV, Polybar #
500 RTV or Sil-Bond 4500 or 6500 or
seal vent pipe.

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: [phone] Fax: [phone] Email: [e-mail]
19
b. Refer to the appropriate drawings in
Appendix D of this manual to
determine common acceptable
configurations of the vent system.
WARNING
Improper venting may result in property
damage and the release of flue gasses that
contain deadly carbon monoxide (CO)
into the building, which can cause severe
personal injury and/ or death.
WARNING
Do not use a barometric damper with this
boiler. This is a positive pressure system.
The use of a barometric damper may
cause flue gases to leak into the boiler
room.
3.4.1 Category II Venting
Category II venting is an engineered system
and shall be designed by a qualified vent
manufacturer and “APPROVED” by the local
authority. The boiler manufacturer takes no
responsibility for vent systems that create
issues and or affect the performance of the
boiler. All jurisdictional codes shall apply in
addition to the following.
1. Common vents serving multiple boilers
shall be designed for negative pressure so
that flue gasses 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 negative 0.001 iwc to negative
0.1 iwc draft at all times from the
minimum firing rate to the maximum
firing rate measured at the outlet of the
boiler.
4. A mechanical draft fan may be required to
maintain the required negative draft.
5. Vertical venting is recommended.Other
horizontal and vertical arrangements may
be acceptable if proven by the vent
manufacturers design calculations.
6. It is recommended that combustion air be
taken from the boiler room. Follow the
guidelines in section 3.3 Other
arrangements may be acceptable if
proven by the vent manufacturers design
calculations.
7. It is recommended that a Carbon
Monoxide detector be installed and
interlocked to the boiler. Consult your
local jurisdiction for additional
requirements.
Boiler
Model
Flue Gas
Flow,
ACFM
@40%XSA
200oF
Comb Air
Req. SCFM
@40%XSA6
0
o
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”
Table 4: Combustion Air and Flue Gas
Requirements
WARNING
A poorly designed Category II negative
vent system can produce positive
pressures in the vent that can spill into the
room and adjoining spaces that can cause
severe personal injury and / or death.

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: [phone] Fax: [phone] Email: [e-mail]
20
3.4.2 Massachusetts
The commonwealth of Massachusetts requires
compliance with regulation 248 CMR 4.00 to
5.00 for installation of sidewall venting gas
appliance as follow.
For all side wall horizontally vented gas fueled
equipment installed in every dwelling, building
or structure used in whole or in part for
residential purpose, including those owned or
operated by Commonwealth and where the
side wall exhaust vent termination is less than
seven (7) feet above finished grade in the area
of the venting, including but not limited to
decks and porches, the following
requirements shall be satisfied.
1. INSTALLATION OF CARBON MONOXIDE
DETECTORS: At the time of installation of
the side wall venting gas fueled
equipment, the installing plumber or
gasfitter shall observe that a hard wired
carbon monoxide detector with an alarm
and battery back-up is installed on the
floor level where the gas equipment is to
be installed. In addition, the installing
plumber or gasfitter shall observe that a
battery operated or hard wire carbon
monoxide detector with an alarm is
installed on each additional level of
dwelling, building or structure served by
the side wall horizontal vented gas fueled
equipment. It shall be the responsibility of
the property owner to secure the service
of a qualified licensed professional for the
installation of hard wired carbon
monoxide detectors.
a. In the event that the side wall
horizontally vented gas fueled
equipment is installed in a crawl
space or an attic, the hard wired
carbon monoxide detectors with
alarm and battery back-up may be
installed on the next adjacent floor
level.
b. In the event that the requirements of
this subdivision cannot be met at the
time of completion of installation, the
owner shall have a period of (30)
days to comply with the above
requirements; provided, however,
that during said (30) day period, a
battery operated carbon monoxide
detector with an alarm shall be
installed.
2. APPROVED CARBON MONOXIDE
DETECTORS. Each carbon monoxide
detector, as required in accordance with
the above provisions, shall comply with
NFPA 720 and be ANSI/UL 2034 listed
and IAS certified.
3. SIGNAGE. A metal or plastic identification
plate shall be permanently mounted to
the exterior of the building at a minimum
height of eight (8) feet above grade
directly in line with the exhaust vent
terminal for the horizontally vented gas
fueled 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 OBSTRUCIONS.”
4. INSPECTION. The state or local gas
inspector of the side wall horizontally
vented gas fueled equipment shall not
approve the installation unless, upon
inspections, the inspector observes
carbon monoxide detectors and signage
installed in accordance with the
provisions of 248 CMR 5.08(2)(a)1
through 4.
a. EXEMPTIONS: The following
equipment is exempt from 248 CMR
5.08(2)(a)1 through 4:
i. The equipment listed in chapter
10 entitled “Equipment Not