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.