Bryan Boilers FREE FLEX User manual

Free Flex I&O manual Revision: 13
P/N 105641-03 Date: 06/24/2022
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
FREE FLEX

CONDENSING BOILER
INSTALLATION & OPERATION MANUAL
AS
ME
H
For service and repair to the boiler, call your heang contractor. When seeking informaon on the boiler from
the manufacturer, provide boiler model and serial number as shown on the rang label.
Boiler Model: Serial Number:
Installaon Date: Type System:
Heang Contractor: Phone/Email:
Address:
WARNING
This manual must only be used by a qualied heating installer/service
technician. Read all instructions in this manual before installing. Perform
steps in the order given. Failure to comply could result in severe
personal injury, death, or substantial property damage.
!

2
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]

 
A. Important Informaon 6
B. Disclaimers and Local Codes 6
C. Test and Inspecons 7
D. Component Descripon 7
E. Touchscreen display. 7
 
A. Installaon Conformance 9
B. Boiler Foundaon 9
C. Clearance and Serviceability 9
 
A. Receiving the Boiler 11
B. Boiler Water and Condensate Connecons 11
C. Condensate Trap/Drain Assembly 12
D. Gas Supply Connecons 13
E. Combuson Air Supply System 13
 
A. General Venng Guidelines 16
B. Venng Design Requirements 17
C. Field Installaon 17
D. General Terminaon 24
E. Vent and Combuson Air Terminaons 28
F. Mulple Appliance Terminaons 30
G. Terminal Installaon 31
H. Polypropylene Venng 33
I. Oponal Room Air for Combuson 33
J. Removing Exisng Appliance 37
K. Special Installaon Requirements for
Massachuses 37
 
A. Electrical 39
B. Gas Supply Requirements 40
C. Sound Pressure Levels 40
D. Pump and Piping Requirements 40
 
A. Pre-Boil Out Flushing of System 42
B. Boiler Out Procedure 42
C. Replacement Boiler Installaons 43
D. Draining and relling the boiler & system 43
E. Boiler Water Treatment 44
 
A. Concert Boiler Control Display Navigaon 45
B. System Check 46
C. Power the Boiler 46
D. Power the Circulators 46
E. Pressurize the Fuel System 46
F. Boiler Commissioning 46
G. Commissioning Free Flex 1000 - Free Flex 3000
46
H. Dual Fuel Free Flex 1500 - Free Flex 6000 -
Switching Fuels 49
I. Commissioning Free Flex 1500 - Free Flex 6000
High Turndown or Dual Fuel 49
J. Finish Commissioning the Free Flex 1000 - Free
Flex 6000 50
K. Re-Starng Aer Prolonged Shutdown 50
L. Tesng Controls and Safety Devices 51
M. Ignion Failure 51
 
A. General Maintenance 52
B. Daily 52
C. Weekly 53
D. Monthly 53
E. Annually 53
F. Ignion Assembly Cleaning 53
G. Burner Assembly Cleaning 54
H. Heat Exchanger Cleaning 54
I. Tube Replacement Procedure 54
J. Safety and Operang Controls 58
K. Troubleshoong 59
 

   
 
 
 
 
 
seller)
 
 

3
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]

 
Figure 1: Free Flex 1000 External Boiler Connecons 8
Figure 2: Free Flex 1500-3000 External Boiler Connecons 8
Figure 3: Free Flex 3500-6000 External Boiler Connecons 8
 
Figure 4: Clearances and Serviceability 10
 
Figure 5: Condensate Drain Trap 12
Figure 6: Condensate Assembly Orientaon 12
 
Figure 7: Vent Terminal Clearances 25
Figure 8: Horizontal Sidewall Terminaon 29
Figure 9: Slopped Roof Terminaon 29
Figure 10: Flat Roof Vent Terminaons 30
Figure 11: Mulple Appliance Direct Vent Terminaon 32
Figure 12: Flexible Vent in Masonry Chimney with Separate Combuson Air Intake 36
 
 
 
Figure 13: Dungs Valve 48
Figure 14: Siemens Valves 48
 
Figure 15: Free Flex 1000-3000 Ignion Assembly 53
Figure 16: Free Flex 3500-6000 Ignion Assembly 54
Figure 17: Panel Removal in Preparaon for Tube Inspecon - Free Flex 1000 55
Figure 18: Panel Removal in Preparaon for Tube Inspecon - Free Flex 1500 - Free Flex 3000 55
Figure 19: Panel Removal in Preparaon for Tube Inspecon - Free Flex 3000 - Free Flex 6000 56
Figure 20: Tube Puller Inseron 57
 

   
 
Figure 21: Typical Horizontal Vent Piping 64
Figure 22: Typical Vercal Pressurized Venng 64
 
Figure 23: Typical Horizontal Air Intake Piping 65
Figure 24: Typical Vercal Air Intake Piping 65
 
Figure 25: Single Boiler, Primary / Secondary 66
Figure 26: Mulple Boilers, Primary Reverse-Return Piping 67
Figure 27: Mulple Boilers, Primary / Secondary Reverse Return Piping 68
Figure 28: Mulple Boilers, Primary / Secondary Piping 69
Figure 29: Mulple Boilers, Primary / Secondary With Indirect Water Heater 70

4
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
 
 
Figure 30: Free Flex 1000 Wiring Diagram 72
Figure 31: Free Flex 1500 To Free Flex 3000 115 VAC Single Phase Wiring Diagram 74
Figure 32: Free Flex 1500 To Free Flex 3000 208 – 230 VAC Single Phase Wiring Diagram 76
Figure 33: Free Flex 2000 To Free Flex 3000 208-460 VAC Three Phase Wiring Diagram 78
Figure 34: Free Flex 1500 To Free Flex 3000 High Turndown 120 - 460 VAC Single or
Three Phase Wiring Diagram 80
Figure 35: Free Flex 1500 To Free Flex 3000 Dual Fuel 120-460 VAC
Single or Three Phase Wiring Diagram 84
Figure 36: Free Flex 3500 To Free Flex 6000 208-460 VAC Three Phase Wiring Diagram 88
Figure 37: Free Flex 3500 To Free Flex 6000 Dual Fuel 208-460 VAC Three Phase Wiring Diagram 92
seller)
 
 

5
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]

 
Table 1: Water Flow Switch Sengs 7
 
Table 2: Clearances and Serviceability 10
 
Table 3: Typical Condensate Flow Rate 12
 
Table 4: Vent and Combuson Air Pipe Diameters
and Maximum Lengths 18
Table 5: Vent and Combuson Air Equivalent Length
Calculaon Worksheet 18
Table 6: Vent Air Pressure Drop Data 19
Table 7: Combuson Air Pressure Drop Data 20
Table 8: Combuson Air and Flue Gas Requirements
21
Table 9: Approved Vent Manufacturers and
Materials 21
Table 10: Stainless Steel and CPVC Vent Adapters 21
Table 11: Polypropylene Vent Adapters 22
Table 12: Stainless Steel Vent and Intake
Terminaons 22
Table 13: Polypropylene Vent and Intake
Terminaons 22
Table 14: Recommended Venng Conguraons
and Material Opons 23
Table 15: Other than Direct Vent Terminal
Clearances 26
Table 16: Table of Acceptable Terminaons 27
 
Table 17: Electrical Requirements 39
Table 18: Gas Supply Requirements 40
Table 19: Sound Pressure Levels 40
Table 20: Minimum Water Flow Rates for Variable
Primary Pumping 41
Table 21: Maximum Water Flow Rate for Variable
Primary Pumping 41
Table 22: Water Flow Rates for Primary/Secondary
Pumping at 20°F ΔT 41
Table 23: Water Flow Rates for Primary/Secondary
Pumping at 40°F ΔT 41
Table 24: Water Flow Rates for Constant Volume
Primary Pumping 42
Table 25: GPM Increase for Glycol System 42
 
Table 26: Chemical Agents and Eects 44
Table 27: Recommended Feed Water Limits 45
 
Table 28: Siemens Nominal Low Fire O2 48
Table 29: Safety Device Tests 51
 
Table 30: Safety and Operang Controls 59
Table 31: General Troubleshoong 60
 
Table 32: Maximum Gas Capacity Of Schedule 40
Pipe 61
Table 33: Equivalent Lengths Of Standard Pipe
Fings And Valves 62
Table 34: Specic Gravity Correcon Factors 62

   
 
 
 
 
 
seller)
 
 

6
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]

A. Important Informaon
The following terms are used throughout this
manual to bring aenon to the presence of hazards
of various risk levels, or to important informaon
concerning product life. It is crical that all personnel
read and follow all the informaon provided in the
boxes marked DANGER, WARNING, CAUTION, and
NOTICE.
DANGER
Indicates an imminently hazardous situaon, which,
if not avoided, will result in death, serious injury or
substanal property damage.
WARNING
Indicates a potenally hazardous situaon, which,
if not avoided, could result in death, serious injury
or substanal property damage.
CAUTION
Indicates a potenally hazardous situaon, which, if
not avoided, may result in moderate or minor injury
or property damage.
NOTICE
Indicates specific instructions on installation,
operaon, or maintenance, which are important but
not related to personal injury hazards.
B. Disclaimers and Local Codes
Installaon must conform to the requirements of
the authority having jurisdicon. In the absence of
such requirements, installaon must conform to the
Naonal Fuel Gas Code, NFPA 54/ANSI Z223.1, and/
or CAN/CGA B149 Installaon Codes. Where required
by the authority having jurisdicon, the installaon
must conform to the Standard for Controls and Safety
Devices for Automacally Fired Boilers, ANSI/ ASME
CSD-1.
Installation, start-up, and maintenance of this
equipment can be hazardous and requires trained,
qualied installers and service personnel. Do not
install, operate, service or repair any components
of this equipment unless you are qualied and fully
understand all requirements and procedures. Trained
personnel refer to those who have completed Thermal
Solutions Service School training specific to this
product.
The boiler heat exchanger is manufactured and
stamped in accordance with ASME Boiler and Pressure
Vessel Code, Secon IV for a maximum allowable
working pressure and operang temperature of 160
psig (1103 kPa) and 210 F(99 C) respecvely. Aqua-stat
is factory set at 200 F (93 C).
NOTICE
Post these instructions and maintain in legible
condion.

7
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
C. Test and Inspecons
Upon the compleon of boiler installaon, nal 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 troubleshoong and servicing the
boiler. In addion, the following tests and inspecons
are made on each boiler at the factory to ensure it
meets our highest safety and funconality standards.
• ASME hydrostac test inspecon
• Electrical components inspecon
• Operang & eciency test
• Final engineering inspecon
• Crang inspecon
DANGER
DO NOT store or use gasoline or other ammable
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 instrucons or if the supplier is
unavailable, contact the re department.
D. Component Descripon
(See Figure 1, Figure 2 and Figure 3)
E. Touchscreen display.
The display provides easy access for viewing
and adjusting boiler operational parameters,
monitoring historical performance characteriscs and
annunciang boiler alarm/lockout condions.
1. Boiler On/O switch.
2. Manual gas shutoff valve. The boiler is
equipped with two manual gas shut o valves,
one located on the incoming gas supply line
outside of the boiler, and the other downstream
of the main gas valve.
3. Main gas supply connecon.
4. Pressure relief valve. The pressure relief
protects the heat exchanger from an over-
pressure condion.
5. Ducted combuson air ange.
6. Flue gas vent outlet. The boiler comes with
a standard AL 29-4C® stainless steel vent
connecon.
7. Boiler water ow switch. The boiler water
ow switch is adjustable within the parameters
listed in Table 1. (Located inside the boiler on
Free Flex 1500 - Free Flex 6000)

Sengs Mode Of Operaon
Switch Closed Switch Open
Minimum 18 13
Maximum 50 45
8. Return water connection. A 3” diameter
Victaulic grooved connecon is provided on
the Free Flex 1000. A 3”, 150# class, ange is
provided on the Free Flex 1500 – 3000. A 6”,
150# class, ange is provided on the Free Flex
3500-6000.
9. Clean out and inspecon. The Free Flex 1000
has a 3” diameter Victaulic grooved connecon
is provided for inspecng and cleaning sediment
from the heat exchanger. The Free Flex 1500-
6000 has a 1” NPT pipe for blow down to clean
sediment from the heat exchanger and a 3”
removable plug for inspecng.
10. Supply water connection. A 3” diameter
Victaulic grooved connecon is provided on
the Free Flex 1000. A 3”, 150# class, ange
is provide on the Free Flex 1500 – 3000. A 6”,
150# class, ange is provided on the Free Flex
3500-6000.

8
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
11. Air vent. The boiler is provided with an internal
dip tube that traps liberated air from the boiler
water. The air vent allows the trapped air to
escape from the boiler.
References 13 to 15 are not used on the Free Flex 1000
12. Boiler reset push buon
13. Boiler water temperature gauge.
14. Boiler water pressure gauge.
References 16 to 18 are only used on Free Flex 3500 – Free
Flex 6000
15. Boiler Hand/O/Auto
16. Push Button Display. The display provides
easy access for viewing and adjusng boiler
operaonal parameters and provides alarm/
lockout codes.
17. Temperature Display. Provides for temperature
set points and actual temperature.






14
15
2
13
1
6
3 4
12
5
117
9
10
14
15
2
13
1
6
3 4
12
5
11
7
9
10

9
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]

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
ed in a correct and safe manner.
WARNING
This boiler requires regular maintenance and service
to operate safely. Follow the instrucons 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 enre manual before aempng installaon,
start-up operaon, or service. Only an experienced,
skilled installer or service agency must perform
installaon and service.
WARNING
This boiler must be properly vented.
This boiler needs fresh air for safe operation
and must be installed so there are provisions for
adequate combuson and venlaon air.
A. Installaon Conformance
Installaon must conform to the requirements of
the authority having jurisdicon. In the absence of
such requirements, installaon must conform to the
Naonal Fuel Gas Code, NFPA 54/ANSI Z223.1, and/
or CAN/CGA B149 Installaon Codes. Where required
by the authority having jurisdicon, the installaon
must conform to the Standard for Controls and Safety
Devices for Automacally Fired Boilers, ANSI/ ASME
CSD-1.
B. Boiler Foundaon
Before uncrating, the boiler location should be
prepared. The boiler should set upon a good level
concrete oor. If the boiler is not level or the oor is
not in good condion, a concrete foundaon 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 combusble ooring.
C. Clearance and Serviceability
See Figure 4 and Table 2 for minimum clearances to
walls, ceilings, or obstrucons. These clearances are
intended as a general recommendaon only. Local
codes must be applied to specic installaons and
the minimum clearances established accordingly.
Provisions must also be made for service, accessibility
and clearance for piping and electrical connecons.
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.

10
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]

Dim Descripon
Free
Flex
1000
Free Flex
1500-3000
Free Flex
3500-6000
AClearance Above Top of Boiler 6” 6” 6”
BFront of Boiler – Burner End 24” 32” 43”
CH From Chimney or Vent Collector measured
horizontally 18” 18” 18”
CV From Chimney or Vent Collector measured
vercally 18” 18” 18”
D Rear of Boiler - opposite burner end 6” 6” 6”
EL Le Side - tube access side on standard con-
strucon 16” 23” 23”
ER
Right Side – tube access side on standard
construcon
(Free Flex 3500-6000)
6” 6” 23”
EC Free Flex 1500 - 3000 only N/A 23” N/A

Boiler
D
A
B
CV
CH
Flue Gas
Vent
Boiler
EL ER

11
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]

A. 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 forkli. Liing
points are also provided to enable over-head liing
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 foundaon
before any piping/electrical connecons are made.
It is recommended that the plasc protecve cover
be le on as long as possible to reduce nish damage
from the installaon.
B. Boiler Water and Condensate Connecons
Do not run any pipes along the tube access panel
side of the boiler. Maintain clearances as shown on
the dimensional drawing for servicing of the boiler
tubes. (See Figure 4 and Table 2). All piping should
be designed and installed to avoid any loadings on
the boiler connecons or piping.
1. Flow Connecon
a. The system supply and return ow connecons
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
heang system for draining and servicing.
2. Safety Relief Valve
a. Safety relief valve(s) are shipped loose.
Connecons 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 shuto valves are to be placed between
the relief valve and the appliance or in the
discharge piping. Avoid over-ghtening 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 situaon. DO NOT
PLUG THIS RELIEF VALVE.
b. The minimum relief valve seng for standard
systems shall be 30 psig. The system shall
operate with no less than 26 psig at all mes.
c. For systems designed to operate at delta T’s
greater than 40°F, the boiler shall be equipped
with a minimum relief valve seng of 60 psig.
The system shall operate with no less than
50 psig at all mes. This will prevent boiler
water hammer.
3. Expansion Tank Connecons
a. Connecon(s) to an expansion tank are to
be provided by others in the system piping
separate from the boiler.
4. Drain Connecons
a. A drain valve must be installed on the boiler
drain connecon, the same pipe size as this
connecon, to allow draining of the boiler.
5. Condensate Drain Connecon
a. A condensate drain trap is shipped with
the boiler and is provided with a 1” npt
connecon to drain the condensed products
of combuson from the boiler. Use Pipe with
connuous Teon, high temperature silicone
tubing, or other tubing material compable
with ue gas condensate. The condensate
temperature should never exceed 212° 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.
b. The condensate drain trap should be ushed
with water as part of your boiler maintenance
schedule to remove any debris that might
have accumulated over me.

12
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
c. A common condensate pump/sump may
be used. Run separate piping from each
condensate drain to the sump. A common
drain may be used to discharge condensate
from the sump. Consult pump/sump materials
of construcon. 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.

Free Flex
Model
Max Condensate Flow (gph)
1000 11.2
1500 16.8
2000 22.4
2500 27.9
3000 33.5
3500 39.1
4000 44.7
4500 50.3
5000 55.8
5500 61.4
6000 67
d. Consult local authories regarding disposal
of flue gas condensate into public waste
water system. Some jurisdicons require that
condensate be buered before discharge.
This buffering is commonly achieved by
draining the condensate through a limestone
bed. Consult Thermal Soluons or a chemical
treatment company for buering 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.
C. Condensate Trap/Drain Assembly
1. The condensate trap/drain assembly, must be
Installed to the outlet in the rear of the boiler.
a. Mount as shown in Figure 5 and Figure 6
(Outlet of the vent is to be level).
b. Insert wires through grommet on back panel
and plug in the two wires into the bullet plugs
inside the back of the boiler.
2. Purpose
a. The ue gas trap prevents ue gases from
escaping into the boiler room.
b. The oat switch interrupts the limit string in
the event the drainage of the condensate is
blocked.
Float Switch
1" PVC Union
Flue Gas Trap
Vent
Outlet (1" Socket Connection)
Cleanout Port



13
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
E. Combuson Air Supply System
For proper combuson 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 addion to air needed for combuson, sucient
air must be supplied for venlaon as well as other
air consuming equipment that may be present in the
boiler room. Oen when personnel are working in the
boiler room, combuson 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 combuson air, if necessary, for
personnel comfort.
Posive means for supplying an ample amount of
outside air, allowing for the complete combuson of
the gas, must be provided.
Movable combustion air dampers, automatic or
manually adjustable, must be electrically interlocked
with the boiler to prevent boiler operaon if the
dampers are closed.
Combuson air openings must never be blocked or
obstructed in any manner.
The boiler room must be at a posive or neutral
pressure relave to the outdoors. A negave in the
boiler room will result in downdra problems and
incomplete combuson due to the lack of air.
WARNING
Failure to provide an adequate air supply will result
in boiler damage and hazardous condions in the
building (re and asphyxiaon hazard as well as
equipment damage).
The design of combuson air openings MUST comply
with local and/or State codes or the authority having
jurisdicon. As a minimum, combuson air openings
to the boiler room shall be provided as follows:
WARNING
Combustion air provided solely from an indoor
source is discouraged. No dimension for a round or
rectangular opening shall be less than 3”.
D. Gas Supply Connecons
The installation must conform completely to the
requirements of the authority having jurisdicon, or
in the absence of such, requirements shall conform in
the U.S. to the current Naonal Fuel Gas Code, ANSI
Z223.1-1984, or in Canada to the current Natural gas
and propane installaon code (CAN/CSA B149.1-05),
and applicable regional regulations for the class;
which should be followed carefully in all cases.
Authories having jurisdicon should be consulted
before installaons are made. Refer to paragraph
3.5.2 for gas supply requirements.
1. Drip Leg
a. 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 connecon at the boiler. This
connecon should be made with a union so
that the boiler gas train components and
burner may be easily removed for service.
2. Gas Piping Leak Test
a. Aer compleon of the gas-piping hookup,
the installaon must be checked for leaks.
Leaks shall be checked using a soap and water
soluon. 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 shuto valve in the closed
posion 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. Venng of Gas Train Components
a. The MBC (gas valve) has an internal, factory
installed vent limiter re ANSI Z21.18/ CSA 6.3.
Venng required unless otherwise accepted
by the authority having jurisdicon.
b. 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.

14
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
1. Two Permanent Opening Method
a. One opening starng within 12” of the top
of the boiler room and one starng within
12” of the boom of the boiler room shall
be provided. The openings shall be open
directly to the outside or ducted directly to
the outside.
b. When directly open to the outside or ducted
to the outside by vercal ducts, each opening
or duct shall have a minimum free open area
of 1 in2 per 4000 BTU total input rang of the
boiler(s) in the room.
c. If ducted to the outside through horizontal
ducts, each opening or duct shall have a
minimum free area of 1 in2 per 2000 BTU
total input rang of the boiler(s) in the room.
2. One Permanent Opening Method
a. One opening commencing within 12” of
the top of the room shall be provided. The
opening shall be directly to the outside
or shall be ducted to the outside with a
horizontal or vercal duct.
b. The opening or duct shall have a minimum
free area of:
c. 1 in2 / 3000 BTU/hour of the total input rang
of all appliances (boilers) in the room.
d. Addional area must be provided for other air
consuming equipment in the room.
3. Mechanical Air Supply Systems
a. The combuson air supply may be provided
by a mechanical air supply system. If ulized,
the combuson air must be provided from the
outside at a minimum rate of 0.35 3/min.
for every 1000 Btu/hr. input for all appliances
located in the space.
b. If exhaust fans are ulized, addional air shall
be provided to replace the exhausted air.
c. Each boiler and other appliance must be
interlocked to prevent operation when
the mechanical air supply system is not in
operaon.
d. If the combustion air is provided by a
buildings mechanical venlaon system, the
system shall be sized to provide the specied
combuson air in addion to the venlaon
air requirements.
4. Louvers and Grilles are not permied.
a. The required size of openings for combuson,
venlaon, and diluon air shall be based on
the net free area of each opening. Where the
free area through a design of louver, grille, or
screen is new, it shall be used in calculang
the size opening required to provide the free
area specied. Where the louver and grille
design and free area are not new, it shall be
assumed that wood louvers have a 25 percent
free area, and metal louvers and grilles have
75 percent free area. Non-motorized louvers
and grilles shall be xed in the open posion.
5. Screens
a. Screens shall not be smaller than 1/4" mesh.
6. Motorized Louvers
a. Motorized louvers shall be interlocked with
the appliance so thy are proven in the full
ope posion prior to main burner ignion
and during main burner operaon. Means
shall be provided to prevent the main burner
from igning should the louver fail to open
during burner startup and to shut down the
main burner if the louver closes during burner
operaon.
7. Combuson Air Ducts
a. Combuson air ducts shall comply with the
following:
b. Ducts shall be constructed of galvanized steel
or a material having equivalent corrosion
resistance, strength and rigidity.
c. Ducts shall terminate in an unobstructed
space, allowing free movement of combuson
air to the appliances.
d. Ducts shall serve a single space.

15
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
e. Ducts shall not serve both upper and lower
combuson air openings where both such
openings are used. The separaon between
ducts serving the upper and lower combuson
air openings shall be maintained to the source
of combuson air.
f. Ducts shall not be screened where terminang
in an ac space.
g. Horizontal upper combuson air ducts shall
not slope downward toward the source of
combuson air.
h. For informaonal purposes, there are several
codes that address the amount of air and/or
size of the opening(s) in walls for combuson
air.
i. NFPA 54, National Fuel Gas Code (ANSI
Z223.1)
j. ASME CSD-1, Controls and Safety Devices for
Automacally Fired Boilers
k. ASME Secon VI, Recommended Rules for
Care and Operaon of Heang Boilers
l. BOCA, Naonal Mechanical Code
WARNING
Do not locate air intakes where petroleum disllates,
CFC’s, detergents, volatile vapors or any other
chemicals are present. Severe boiler corrosion and
failure will result.
8. Ducted Combuson Air
a. Ducted combuson air can be connected to
the boiler air intake ange. Ducts shall be
constructed of galvanized steel or a material
having equivalent corrosion resistance,
strength and rigidity.
b. Table 4, Table 6, and Table 7 shall be used to
determine the ducted combuson air system
equivalent length.
c. Table Table 5 can be used for calculaons.

16
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]

A. General Venng Guidelines
In order to properly vent this boiler, the installer
must select and install a venng system that meets
all requirements specied in this secon, as well as
following the instrucons provided by the venng
system manufacturer:
1. Install vent system in accordance with Naonal
Fuel Gas Code, ANSI Z223.1/NFPA 54 or Natural
Gas and Propane Installation Code, CAN/
CSA B149.1 Installaon Code for Canada, or,
applicable provisions of local building codes.
2. If this boiler is being installed in Massachuses,
follow the Massachuses Code Instrucons
printed near the end of this secon in Step K.
3. Vent/combustion system materials that are
approved for use with this appliance are listed
in Table 10. Venng manufacturers not listed
in this manual may be acceptable. It is the
responsibility of the installer or vent supplier to
use compable adapters and materials.
a. It is recommended to consult with venng
professionals and designers when determining
the vent system for this appliance.
b. This boiler is shipped with a AL29-4C© Heat-
Fab Saf-T-Vent connection.
c. Alteration of the boiler vent connection is
prohibited.
4. Recommended ue system material is AL29-
4C©. Other materials may be used that meet
the following requirements:
a. Flue system material shall be capable of
connuous operaon at 230°F or higher.
b. Flue system material shall have the same
corrosion resistance to ue gas condensaon
as AL29-4C©.
c. Flue system and material shall be cered to
UL1738 - Venng Systems For Gas-Burning
Appliances Categories II, III, and IV.
5. Do not reduce the diameter of the vent pipe.
The vent pipe must not be smaller than the vent
connector on the boiler.
WARNINGWARNING
This appliance must not be installed in a room
under negave pressure. These direct vent gas red
appliances are allowed a maximum leakage of 2%
from the venng/combuson chamber and 8% from
the air inlet poron when pressurized to operang
condions in a neutral pressure room. An equipment
room under negave pressure could deplete the
combuson air supply to the appliance and cause
leakage of ue gas from the venng system.
Exhaust fans installed in equipment rooms can
create negave pressure condions strong enough
to cause nuisance shutdowns of the appliance.
Failure to install the appliance in accordance with
this manual can cause property damage, personal
injury, or loss of life.
!
6. Enclose vent passing through occupied or
unoccupied spaces above the appliance with
material having a re resistance rang at least
equal to the rang of adjoining oor or ceiling.
7. For flue gas venting, have horizontal runs
sloping upwards not less than ¼ inch per foot
(21 mm/m) from the boiler to the vent terminal.
NOTICENOTICE
Common venting with other manufacturers'
appliances or dierent Thermal Soluons models
is prohibited.
It is the Responsibility of the installing contractor or
venng designers to comply with naonal and local
codes and follow best industry pracces for installing
vent support, drainage, and pitch.
Do not exceed maximum vent/combustion air
system length.
NOTICENOTICE
Do not exceed maximum vent / combinaon air
system length.

17
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
C. Field Installaon
1. A factory installed cast aluminum or steel ring
provides a means for air intake connecon.
2. A factory installed vent connector provides a
means for connecon to stainless steel venng.
3. Vent and combuson air intake pipe must be
supported at intervals no less than (5) feet
apart. The completed vent system must be
rigid and able to withstand impacts without
collapse, to allow uniform ow of combuson
air and ue gas.
4. Plan venng system to avoid possible contact
with plumbing or electrical wires. Start at the
vent connector and work towards the vent
terminaon.
5. Design the air intake system to allow 3/8”
(9.5mm) of thermal expansion per 10 . (3m)
of CPVC/PVC pipe. Runs of 20 . (6.1m) or
longer that are restrained at both ends must
have an oset.
a. PVC combustion air pipe joints must be
cleaned with primer and glued with cement.
Follow all manufacturer instructions and
drawings when preparing pipe ends for
joining and using the primer and the cement.
6. Size and cut wall opening such that a minimal
clearance is obtained and to allow easy
inseron of vent pipe.
WARNINGWARNING
Failure to follow these instructions could cause
products of combustion to enter the building,
resulng in severe property damage, personal injury,
or death.
Use CPVC vent components within any interior space
where air cannot circulate freely, including through
vercal or horizontal chase ways, inside a stud wall,
in closets, and through wall penetraons.
The use of cellular core PVC (ASTM F891), cellular
core CPVC or Radel (polyphenolsulfone) is prohibited.
All condensate that forms in the vent must be able
to drain back to the heat exchanger.
!
8. This appliance operates under condions that
permit condensaon in the heat exchanger
and the ue gas venng. This appliance shall
be installed so as to prevent accumulaon of
condensate, and where necessary, have means
provided for drainage of condensate.
9. If possible, slope horizontal combustion air
pipe minimum 1/4 in/ (21 mm/m) downward
towards terminal. If not, slope towards the
appliance.
10. It is recommended that a Carbon Monoxide
detector be installed and interlocked to the
appliance. Consult your local jurisdicon for
addional requirements.
B. Venng Design Requirements
At the discreon of the installing contractor, the
venng system can be designed by consulng
with approved venng engineers or by using the
equivalent length method in this manual.
1. Engineered Venng Method
(Recommended Method) Using the operang
characteriscs and required condions, an
individual or common venting system can
be designed to ensure the reliability of the
appliance(s).
a. Flue gas temperatures and ow rates can be
found in Table 8.
b. The pressure at the ue outlet of the appliance
at any given ring rate must be within the
range of negave 0.25" W.C. to posive 0.5"
W.C.
c. The pressure at the intake of the appliance at
any given ring rate must be within the range
of 0.0" WC to posive 0.1" WC.
d. Manifolded venting without backflow
prevention can allow flue gas from one
appliance to interact with the other appliances
in the system. Common venng systems must
be designed with backow protecon.
2. Equivalent length method: Do not exceed
maximum vent/combuson air lengths listed in
Table 6. Equivalent lengths of ngs are given
in Table 7.

18
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]

Free
Flex
Model
Combustion Air Length Vent Length
Pipe Dia. In (mm) Minimum Ft. (m) Maximum . (m) Pipe Dia. In (mm) Minimum Ft. (m) Maximum . (m)
1000 6 (160) 0 100 (45.7) 6 (160) 3 (0.9) 100 (45.7)
8 (200) 0 100 (45.7) 8 (200) 3 (0.9) 100 (45.7)
1250 6 (160) 0 100 (45.7) 6 (160) 3 (0.9) 100 (45.7)
8 (200) 0 100 (45.7) 8 (200) 3 (0.9) 100 (45.7)
1500 6 (160) 0 100 (45.7) 6 (160) 3 (0.9) 100 (45.7)
8 (200) 0 100 (45.7) 8 (200) 3 (0.9) 100 (45.7)
2000 8 (200) 0 100 (45.7) 8 (200) 3 (0.9) 100 (45.7)
2500 10 (250) 0 100 (45.7) 10 (250) 3 (0.9) 100 (45.7)
3000 10 (250) 0 100 (45.7) 10 (250) 3 (0.9) 100 (45.7)
3500 12 (315) 0 100 (45.7) 12 (315) 3 (0.9) 100 (45.7)
4000 12 (315) 0 100 (45.7) 12 (315) 3 (0.9) 100 (45.7)
4500 14 (356) 0 100 (45.7) 14 (356) 3 (0.9) 100 (45.7)
5000 14 (356) 0 100 (45.7) 14 (356) 3 (0.9) 100 (45.7)
5500 14 (356) 0 100 (45.7) 14 (356) 3 (0.9) 100 (45.7)
6000 14 (356) 0 100 (45.7) 14 (356) 3 (0.9) 100 (45.7)
Note:
Contact factory for assistance on maximum vent length applicaons.
This table applies to all listed vent/combuson air system opetoins.

Component
Combustion Air Vent
Equivalent
Length Per
Piece
XQuanty =
Subtotal
Equivalent
Length
Equivalent
Length Per
Piece
XQuanty =
Subtotal
Equivalent
Length
Straight Pipe X = A = D
90° Elbow X = B = E
45° Elbow X = C= F
Combustion Air Total
Equivalent Length =Vent Total Equivalent Length =
Notes:
1. Total equivalent length cannot exceed maximum 100 equivalent feet (30.48 Meters) in length.
2. Combuson air and vent terminaons do not cound towards total equivalent length.

19
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
Combined pressure drop through the Vent duct shall not exceed 100 equivalent feet (30.84 meters).

Flue Vent Diameter
in. (mm)
Straight Length Equivalent
/ (m/m)
90° Elbow Equivalent
/ (m/m)
45° Elbow Equivalent
/ (m/m)
Velocity
(fpm)
Free Flex 1000 Pressure Drop in Equivalent Feet (Meters)
6 (160) 1 (0.304) 10 (3.04) 5 (1.524) 1534
8 (200) 0.22 (0.07) 2.22 (0.676) 1.11 (0.338) 863
Free Flex 1500 Pressure Drop in Equivalent Feet (Meters)
8 (200) 0.56 (0.17) 5.88 (1.792) 2.86 (0.871) 1296
10 (250) 0.174 (0.053) 1.75 (0.533) 0.87 (0.265) 829
Free Flex 2000 Pressure Drop in Equivalent Feet (Meters)
8 (200) 1 (0.03) 10 (3.048) 5 (1.524) 1728
10 (250) 0.31 (0.09) 3.125 (0.952) 1.56 (0.475) 1106
12 (315) 0.12 (0.036) 1.19 (0.362) 0.59 (0.179) 768
Free Flex 2500 Pressure Drop in Equivalent Feet (Meters)
8 (200) 1.56 (0.047) 16.67 (5.081) 8.33 (2.538) 2158
10 (250) 0.478 (0.145) 5 (1.524) 2.44 (0.743) 1381
12 (315) 0.183 (0.055) 1.852 (0.564) 0.92 (0.28) 959
Free Flex 3000 Pressure Drop in Equivalent Feet (Meters)
8 (200) 2.22 (0.068) 25 (7.62) 11.11 (3.386) 2591
10 (250) 0.68 (0.207) 7.14 (2.176) 3.57 (1.088) 1658
12 (315) 0.267 (0.081) 2.7 (0.822) 1.35 (0.411) 1152
Free Flex 3500 Pressure Drop in Equivalent Feet (Meters)
10 (250) 0.455 (0.138) 4.55 (1.386) 2.727 (0.831) 1935
12 (315) 0.172 (0.052) 1.724 (0.525) 0.862 (0.252) 1344
14 (356) 0.08 (0.024) 0.77 (0.234) 3.85 (1.173) 987
Free Flex 4000 Pressure Drop in Equivalent Feet (Meters)
10 (250) 0.95 (0.289) 10 (3.048) 4.76 (4.76) 2212
12 (315) 0.37 (0.112) 3.7 (1.127) 1.85 (0.563) 1536
14 (356) 0.16 (0.048) 1.64 (0.499) 0.81 (0.248) 1129
Free Flex 4500 Pressure Drop in Equivalent Feet (Meters)
12 (315) 0.47 (0.143) 4.76 (1.45) 2.33 (0.71) 1729
14 (356) 0.21 (0.064) 2.08 (0.633) 1.03 (0.313) 1270
16 (406) 0.1 (0.03) 1.02 (0.31) 0.51 (0.155) 972
Free Flex 5000 Pressure Drop in Equivalent Feet (Meters)
12 (315) 0.57 (0.173) 5.71 (1.74) 2.85 (0.868) 1920
14 (356) 0.25 (0.076) 2.56 (0.78) 1.27 (0.387) 1410
16 (406) 0.13 (0.039) 1.27 (0.387) 0.63 (0.192) 1080
Free Flex 5500 Pressure Drop in Equivalent Feet (Meters)
12 (315) 0.69 (0.21) 6.9 (2.103) 3.45 (1.051) 2112
14 (356) 0.31 (0.094) 3.13 (0.954) 1.54 (0.469) 1552
16 (406) 0.15 (0.045) 1.52 (0.463) 0.76 (0.231) 1188
Free Flex 6000 Pressure Drop in Equivalent Feet (Meters)
12 (315) 0.83 (0.252) 8.33 (2.538) 4.17 (1.271) 2304
14 (356) 0.36 (0.109) 3.7 (1.127) 1.85 (0.563) 1693
16 (406) 0.19 (0.057) 1.82 (0.554) 0.91 (0.277) 1296

20
Bryan Steam, LLC www.bryanboilers.com
Phone: [phone] N Chili Ave, Peru, IN 46970 [email protected]
Combined pressure drop through Combuson duct shall not exceed 100 equivalent feet (30.84 meters).

Flue Vent Diameter
in. (mm)
Straight Length Equivalent
/ (m/m)
90° Elbow Equivalent
/ (m/m)
45° Elbow Equivalent
/ (m/m)
Velocity
(fpm)
Free Flex 1000 Pressure Drop in Equivalent Feet (Meters)
6 (160) 0.6 (0.182) 6.25 (1.905) 3.13 (0.954) 1121
8 (200) 0.13 (0.039) 1.32 (0.402) 0.658 (0.2) 631
Free Flex 1500 Pressure Drop in Equivalent Feet (Meters)
8 (200) 0.3 (0.091) 3.03 (0.923) 1.49 (0.045) 946
10 (250) 0.09 (0.027) 0.92 (0.28) 0.46 (0.14) 605
Free Flex 2000 Pressure Drop in Equivalent Feet (Meters)
8 (200) 0.53 (0.161) 5.26 (1.603) 2.63 (0.801) 1264
10 (250) 0.164 (0.049) 1.64 (0.499) 0.82 (0.249) 809
12 (315) 0.063 (0.019) 0.63 (0.192) 0.314 (0.095) 562
Free Flex 2500 Pressure Drop in Equivalent Feet (Meters)
8 (200) 0.83 (0.0250) 8.3 (2.529) 4.17 (1.271) 1576
10 (250) 0.26 (0.079) 2.56 (0.78) 1.28 (0.39) 1009
12 (315) 0.1 (0.03) 0.98 (0.298) 0.49 (0.149) 701
Free Flex 3000 Pressure Drop in Equivalent Feet (Meters)
8 (200) 1.19 (0.362) 12.5 (3.81) 5.9 (1.798) 1895
10 (250) 0.37 (0.112) 3.7 (1.127) 1.85 (0.563) 1213
12 (315) 0.14 (0.042) 1.41 (0.429) 0.7 (0.213) 842
Free Flex 3500 Pressure Drop in Equivalent Feet (Meters)
10 (250) 0.39 (0.118) 3.92 (1.194) 1.96 (0.597) 1414
12 (315) 0.15 (0.045) 1.49 (0.454) 0.75 (0.228) 982
14 (356) 0.07 (0.021) 0.67 (0.204) 0.33 (0.1) 722
Free Flex 4000 Pressure Drop in Equivalent Feet (Meters)
10 (250) 0.51 (0.155) 5.13 (1.563) 2.56 (0.78) 1616
12 (315) 0.2 (0.06) 1.96 (0.597) 0.97 (0.295) 1122
14 (356) 0.087 (0.026) 0.87 (0.265) 0.44 (0.134) 825
Free Flex 4500 Pressure Drop in Equivalent Feet (Meters)
12 (315) 0.25 (0.076) 2.5 (0.762) 1.23 (0.374) 1264
14 (356) 0.11 (0.033) 1.1 (0.335) 0.55 (0.167) 928
16 (406) 0.054 (0.016) 0.55 (0.167) 0.27 (0.082) 711
Free Flex 5000 Pressure Drop in Equivalent Feet (Meters)
12 (315) 0.31 (0.094) 3.13 (0.954) 1.54 (0.469) 1403
14 (356) 0.14 (0.042) 1.35 (0.411) 0.68 (0.207) 1030
16 (406) 0.067 (0.02) 0.67 (0.204) 0.34 (0.103) 789
Free Flex 5500 Pressure Drop in Equivalent Feet (Meters)
12 (315) 0.37 (0.112) 3.7 (1.127) 1.85 (0.563) 1544
14 (356) 0.17 (0.051) 1.64 (0.499) 0.82 (0.249) 1134
16 (406) 0.082 (0.024) 0.81 (0.246) 0.41 (0.124) 868
Free Flex 6000 Pressure Drop in Equivalent Feet (Meters)
12 (315) 0.44 (0.134) 4.55 (1.386) 2.22 (0.676) 1684
14 (356) 0.2 (0.06) 1.96 (0.597) 0.98 (0.298) 1237
16 (406) 0.097 (0.295) 0.97 (0.295) 0.49 (0.149) 947