Bryan Boilers FF1000, FF1500, FF2000, FF2500, FF3000 Installation & Operation Manual

Form: 2435

i

For service and repair to the boiler, call your heating contractor. When seeking information on

label.

Boiler Model:

Serial Number:

Installation Date:

Type System:

Heating Contractor:

Phone/Email:

Address:

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

FREE FLEX

High Efficiency, Low Emission

CONDENSING BOILER

INSTALLATION & OPERATION MANUAL

the boiler from the manufacturer, provide boiler model and serial number as shown on the rating

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

ii

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Table of Contents

1 Introduction ........................................................................................................................................................................ 6

1.1 Important Information ......................................................................................................................................... 6

1.2 Disclaimers and Local Codes .............................................................................................................................. 6

1.3 Test and Inspections .............................................................................................................................................. 7

1.4 Component Description ....................................................................................................................................... 8

2 Pre-Installation ............................................................................................................................................................... 10

2.1 Installation Conformance ................................................................................................................................. 10

2.2 Boiler Foundation ................................................................................................................................................ 10

2.3 Clearances and Serviceability ......................................................................................................................... 10

3 Installation ....................................................................................................................................................................... 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

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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Form: 2435

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Revision: 9
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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

4 SYSTEM 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

5 Service, 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

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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Form: 2435

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Revision: 9
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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

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

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Revision: 9
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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

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

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Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

1 Introduction

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.

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.

NOTICE

Indicates specific instructions on
installation, operation, or maintenance,
which are important but not related to
personal injury hazards.

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

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Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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.

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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Form: 2435

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Mode Of Operation

Switch

13

45

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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 over­pressure condition.

6. Ducted combustion air flange.

7. Flue gas vent outlet. The boiler comes

with a standard AL 29-4C® stainless steel
vent connection.

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.

8. Boiler water flow switch. The boiler

water flow switch is adjustable within the
parameters listed in Table 1.

Settings

Switch
Closed

Open

Minimum 18

Maximum 50

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.

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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Form: 2435

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Revision: 9
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Figure 1: FF1000 External Boiler

Connections and Components

Figure 2: FF1500 - 3000 External Boiler

Connections and Components

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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Form: 2435

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Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

2 Pre-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.

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.

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

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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Dim

Description

1000

1500-3000

Clearance

Boiler

Front of Boiler
– Burner End

From Chimney

horizontally

Dim

Description

1000

1500-3000

From Chimney

vertically

Rear of Boiler -

end

Left Side – tube

construction

ER

Right Side

6”

6”

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

C

A

V

Flue Gas
Vent

C

H

CV

or Vent
Collector
measured

D

opposite burner

18” 18”

6” 6”

D

Boiler

B

EL

access side on
standard

16” 23”

E

L

E

R

Boiler

Figure 3: Clearances and Serviceability

Table 2: Clearances and Serviceability

A

Above Top of

B

or Vent

CH

Collector
measured

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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6” 6”

24” 25-5/8”

18” 18”

Form: 2435

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Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

3 Installation

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.

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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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

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Table 3: Typical Condensate Flow Rate

Model

Max Condensate Flow (gph)

FF1000

7

FF1500

10.5

FF2000

16

FF2500

21.5

FF3000

27

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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.

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.

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.

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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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

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Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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,

Figure 5: FF1500 - 3000 Condensate Drain

Trap

the remainder of the gas train joints down
stream of the main motorized gas valve shall
be tested for leaks.

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.

3.2.7.3 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.

3.2.7.2 Gas Piping Leak Test

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Form: 2435

15

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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:

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 in2 per 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 in2 per 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.

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

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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

16

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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. Non­motorized louvers and grilles shall be fixed in
the open position.

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.

3.3.2.2 Screens

Minimum Screen Mesh Size:

Screens shall not be smaller than 1/4 “ mesh.

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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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

17

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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.

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. 

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.

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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

18

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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.

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.

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.

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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

19

Boiler
Model

Flue Gas

Flow,

@40%XSA

200oF

Comb Air

Req. SCFM

0oF

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”

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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

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.

ACFM

@40%XSA6

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.

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.

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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Form: 2435

20

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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

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Form: 2435

21

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Required To Be Vented” in the
most current edition of NFPA 54
as adopted by the Board; and

ii. Product Approved side wall

horizontally vented fueled
equipment installed in a room or
structure separate from the
dwelling, building or structure
used in whole or in part for
residential purposes.

b. MANUFACTURER REQUIREMENTS-

GAS EQUIPMENT VENTING SYSTEM
PROVIDED. When the manufacturer of
Product Approved side wall
horizontally vented gas equipment
provides a venting system design or
venting system components with the
equipment, the instructions provided
by manufacturer for installation of the
equipment and the venting system
shall include:

i. Detailed instructions for the

installation of the venting system
design or the venting system
components; and

ii. A complete parts list for the vent

system design or venting system.

c. MANUFACTURER REQUIREMENTS-

GAS EQUIPMENT VENTING SYSTEM
NOT PROVIDED. When the
manufacturer of a Product Approved
side wall horizontally vented gas
fueled equipment does not provide
the parts for venting the flue gases,
but identifies “special venting
systems”, the following requirements
shall be satisfied by the manufacturer:

i. The referenced “special venting

system” instructions shall be
included with the appliance or
equipment installation
instructions; and

ii. The “special venting systems”

shall be Product Approved by the
Board, and the instructions for the
system shall include a parts list
and detailed installation
instructions.

d. A copy of all installation instructions

for all Product Approved side wall
horizontally vented gas fueled
equipment, all venting instructions, all
parts lists for venting instructions,
and/or all venting design instructions
shall remain with appliance or
equipment at the completion of the
installation instructions.

3.4.3 Combustion Air and Venting

Requirements for Canada

Canadian Standard CAN/CSA-B149.1-05,
Natural gas and propane installation code
specifies venting systems and air supply for
appliances in Section 8. Paragraph 8.1.4 states
“Air supply shall be provided in accordance
with Clause 8.4 when either an appliance or a
combination of appliances has a total input
exceeding 400,000 Btuh. Air supply is defined
as combustion air, excess air, flue gas dilution
air, primary air, secondary air, and ventilation
air. The air supply requirements below are a
summation of Clause 8.4 specific to this
boiler.

3.4.3.1 Air Supply Requirements per

CAN/CSA-B149.1-05 for
Appliances having an input
exceeding 400 MBH.

Ventilation Air: an opening for ventilation air
at the highest point that opens to the
outdoors shall provide Ventilation of the
space. The cross sectional area of this
opening shall be at least 10% of the area
required for combustion air, but in no case
shall the cross-sectional area be less that 10 in2
(6500mm2).

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Form: 2435

22

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Combustion Air: For combustion air where
the air supply is provided by natural airflow
from outdoors, in addition to the opening for
ventilation air, there shall be permanent
opening having a total cross-sectional free
area of not less than 1 in2 for each 30,000
BTU/hr. (70 mm2 for each kW) of the total
rated input of the boiler(s). The location of
the opening(s) shall not interfere with the
openings for ventilation air. Please refer to
CAN/CSA-B149.1-05, Para. 8.4.4, for
combustion air openings if there are natural
draft, fan assisted or power draft assisted
equipment in the space.

When an air supply duct is used to supply
combustion air, it’s discharge opening shall be
located where there is no possibility of cold
air affecting steam or water lines or other
temperature sensitive equipment.

3.4.3.2 Combustion Air Supply Dampers,

Louvers, and Grilles

The free area of the combustion air supply
opening shall be calculated by subtracting the
blockage area of all fixed louvers, grilles or
screens from the gross area of the opening.

When combustion air is supplied by
mechanical means, an airflow sensing device
shall be installed and wired into the safety
limit circuit of the primary safety control to
shut off the gas in the even a an air supply
failure.

3.4.3.4 Appliance Venting per CAN/CSA-

B149.1-05

Paragraph 8.9 of CAN/CSA-B149.1-05
addresses “Appliance Venting”. Paragraphs

8.9 through 8.31 address many facets of flue
gas vents, many of which do not apply to the
this boiler, which is a Category IV listed
appliance requiring the use of special venting
systems as previously described.

NOTICE

Please note that the information provided
in this manual relative to the Canadian
Standard is not meant to be all-inclusive.
Reading the entire Standard is strongly
suggested. The final approval of all
system designs must be acceptable to the
authority having jurisdiction.

Openings in a fixed louver, grille, or screen
shall have no dimension smaller than ¼” (6
mm).

No manually operated damper or manually
operated adjustable louvers are permitted.

A motorized damper or louvers shall be
interlocked so the burner(s) cannot operate
unless the damper or louver is in the fully
open position.

3.4.3.3 Mechanical Combustion Air

Supply

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• Venting for Category IV appliances

shall be as specified or furnished by
the manufacturer of the listed
appliance. This boiler is a Category
IV appliance requiring the use of
special vent that is certified.

• A special venting system shall be

installed in accordance with the terms
of it’s listing and the vent
manufacturers certified installation
manual.

• A flue gas vent or a vent connector

shall not be installed in either a duct
or a shaft used for return air, hot air,
ventilating air, or combustion air.

• An appliance that operates at a

positive vent pressure shall not be
connected to a venting system serving

Form: 2435

23

Table 5: Electrical Requirements

FF1000

Voltage

FLA

CCA

MHP

MA

120/1/60

6.6

2.6

.46

4

FF1500

Voltage

FLA

CCA

MHP

MA

208-

FF2000 to FF3000

Voltage

FLA

CCA

MHP

MA

208-

208-

480/3/60

6.6

2.6

3.2

4

FLA = Full Load Amps : CCA = Control

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

any other appliance. This boiler
operates at a positive vent pressure.

• A factory-built chimney used for

venting an appliance shall be certified.

3.5 Requirements

3.5.1 Electrical

WARNING

All electrical connections must conform to
the National Electrical Code, ANSI /
NFPA 70 and / or CSA C22.1 Electrical
Code and all other State and Local codes.

A separate electrical circuit must be run from
the main electrical service with an over­current device/disconnect in the circuit. A
service switch is recommended and may be
required by some local jurisdictions. Locate
the service switch such that the appliance can
be shut off without exposing personnel to
danger in the event of an emergency. See
Table 5 for available voltages.

240/1/60

240/1/60

240/3/60

6.9 2.6 1.1 4.3

8.3 2.6 1.5 5.7

9.5 2.6 3 6.9

Circuit Amps : MHP = Motor Horse Power :
MA = Motor Amps

Connect field supplied safety limits or devices
using proper terminals provided in boiler
electrical cabinet. Refer to wiring diagram
supplied with boiler for wiring information.

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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See Appendix H for sample-wiring diagrams.
An as-built wiring diagram is included with
every boiler when it ships. Contact a Bryan
Steam Representative or visit the website
(www. thermalsolutions.com) for current
wiring options.

Form: 2435

24

Capacity

(SCFH)

Inlet
(nps)

Min.
(iwc)

Max.
(iwc)

FF1000

1000

1 4 14

FF1500

1500

2 4 14

FF2000

2000

2 4 14

FF2500

2500

2 4 14

FF3000

3000

2 4 14

Table 7 Sound Pressure Levels

Decibel Levels

Tube

FF1000

FF1500

67

60

61

63

Table 7 Sound Pressure Levels

Decibel Levels

Tube

FF2000

67

60

61

63

FF2500

62

62

66

61

FF3000

62

62

66

61

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

3.5.2 Gas Supply Requirements

Refer to Table 6 for minimum and maximum
gas supply pressure. When the gas supply
pressure exceeds the maximum, an additional
field supplied step down regulator will be

Model Front Rear

Side

required to reduce the supply pressure. For
proper gas supply sizing refer to Appendix A.

NOTICE

The step down regulator shall be installed
at least 60 pipe diameters from the boiler
gas inlet manual shutoff valve. This will
ensure proper gas regulation for
establishing main flame reliably.

Model

3.5.4 Pump and Piping Requirements

Pump piping and system piping must meet
the requirements of local codes and
jurisdictions. Good engineering practices
should be followed and considered for each
piping system used.

It is advised that the circulating pump for
each boiler be installed as close to the boiler
as possible in the line to the return connection
such that system water is pumped towards the
boiler.

Right
Side

Table 6: Gas Supply Requirements

3.5.3 Sound Pressure Levels

Sound pressure levels were measured at 4­1/2’ above the floor and 3’ from the boiler at
the front, rear and two sides. See Table 7 for
decibel readings.

Model Front Rear

Side

Right
Side

Installing circulating pumps so that the water
is pumped away from the boiler is rarely
recommended.

Means to eliminate air from the boiler/piping
systems is a must. It is advised that an air
separator be installed as close as practical to
each boiler in the outlet pipe. Further, an air
vent should be installed at all high points
throughout the piping system.

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Minimum Flow Rate

Δ P

(ft)

High Fire

Δ T

FF1000

19

.51

100F

FF1500

29

.37

100F

FF2000

38

.65

100F

FF2500

48

.8

100F

FF3000

57

1.15

100F

Maximum Flow Rate

Δ P

(ft)

High Fire

Δ T

FF1000

95

12.7

20F

FF1500

143

9.2

20F

FF2000

190

16.3

20F

FF2500

238

20

20F

FF3000

285

28.7

20F

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

It is recommended that a water meter be
installed in the make-up water system to the
boiler system. Scheduled recording of the

Model

gpm

water meter register will show an indication of
a potential slow system leak in addition to
providing insight into any system problems.
Also, make-up water as well as water for the
initial system fill should be provided through
a water softener. Additionally, chemical
treatment of the system water is advisable.
Contact a qualified boiler water chemical

Table 8 Minimum Water Flow Rates for

Variable Primary Pumping

treatment company for their
recommendations. See section 3.8 for more
information.

Model

gpm

See Appendix G for boiler water flow
pressure drop data and Appendix F for typical
boiler piping arrangements.

3.5.4.1 Water Flow Rates (Variable Primary

Pumping Systems)

Variable primary pumping systems shall be
capable of delivering no less than the
minimum and no more than the maximum
specified in Table 8 and Table 9 for each
boiler connected in the system.

Table 9 Maximum Water Flow Rates for

Variable Primary Pumping

WARNING

Do not use Table 8 or Table 9 to size a
constant volume pump.

3.5.4.2 Water Flow Rates (Primary /

Secondary Systems)

Each boiler connected to a secondary loop of
a primary / secondary pumping system shall
have a constant volume pump sized in
accordance with Table 10 or Table 11.

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20 F Δ T Flow Rate

High

Δ T

Low

Δ T

FF1000

95

12.7

20F

4F

FF1500

143

9.2

20F

4F

FF2000

190

16.3

20F

4F

FF2500

238

20

20F

4F

FF3000

285

28.7

20F

4F

40 F Δ T Flow Rate

High

Δ T

Low

Δ T

FF1000

48

3.18

40F

8F

FF1500

71

2.3

40F

8F

FF2000

95

4.08

40F

8F

FF2500

119 5 40F

8F

FF3000

143

7.18

40F

8F

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Model

gpm

Δ P

(ft)

Fire

Fire

Table 10 Water Flow Rates for Primary /

Secondary Pumping 20F ΔT

Model

gpm

Δ P

(ft)

Fire

Fire

Table 11 Water Flow Rates for Primary /

Secondary Pumping 40F ΔT

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Glycol

Concentration

50%

24%

30%

14%

Revision: 9
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3.5.4.3 Water Flow Rates (Constant

Volume Primary Pumping Systems)

A constant volume primary pumping system
shall be sized so that the flow rate specified in
Table 10 or Table 11 can be maintained
through each boiler connected to the system.

3.5.4.4 Water Flow Rates for Glycol

For glycol systems the gpm in Table 8, Table
9, Table 10, and Table 11 will increase as
specified in Table 12.

GPM Percent Increase

Table 12 GPM Increase for Glycol Systems

3.6 Before Placing Boiler In Operation

3.6.1 Pre-Boil Out Flushing Of System

Much of the dirt and contamination in a new
hot water system can be flushed out before
the boil out of the system. First, flush the
system of waste with clear water. The boiler
and circulating pumps must be isolated
through the successive zones of the system to
waste, carrying metal shavings, dirt, pipe joint
compound, etc. with it. Follow with a
chemical flush.

WARNING

Be CERTAIN that the chemicals used to
flush and boil-out the boiler and system
contain NO CHLORIDES. The boiler is
fabricated with austenitic stainless steels
that can be severely damaged when
exposed to chlorides.

The removal of pipe chips and other debris
from the system before opening the isolation
valves to the boiler and pumps will help to
protect this equipment from damage by such
debris.

In combination with system contamination,
bacteria from ground water boiler water may
produce objectionable odors, sometimes
resembling the odorant used in natural gas. It
is important to keep these fumes from air
intakes that would distribute them throughout
the building.

3.6.2 Boil Out Procedure

WARNING

The boil out procedure outlined must be
performed by, or under the direct
supervision of, a qualified technician.
The chemicals used present a hazard of
burns and physical injury if mishandled.
Always use a suitable facemask, goggles,
protective gloves, and garments when
handling caustic chemicals. Do not
permit the chemical to come into contact
with skin or clothing. Always follow the
safety precautions on the container's
label. Add chemicals slowly and in small
amounts to prevent excessive heat and
agitation.

The boil out of the boiler and system is
neither difficult nor expensive. The chemicals
needed for cleaning are readily available. Tri­sodium phosphate, and sodium hydroxide
(lye) are the most commonly used chemicals.
Be certain the chemicals used contain NO
CHLORIDES. Use only one type of solution
in the system. The amount of chemical
required will vary according to conditions, but
one pound per fifty gallons of water is
suggested.

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Fill the system with this solution, venting all
air. Then, with the circulating pump running,
bring the system to design or operating
temperature. After circulating water for two
to three hours, the system should be drained
completely, and refilled with fresh, softened
water see section 3.8. Usually enough of the
cleaning solution will adhere to the piping to
result in an alkaline solution satisfactory for
operation. A pH reading between, 8.3 – 10.5
is preferred. If necessary, to increase the pH,
a small amount of cleaner may be added.

3.6.3 Replacement Boiler Installations

Clean or replace all system piping and heating
units.

Arrange for chemical or mechanical cleaning
of the entire system. A chemical treatment
company should be consulted for the proper
means of any chemical cleaning. Replace any
piping that is deteriorated beyond safe or
cleanable condition.

Flush the system clean, being certain to isolate
the boiler.

WARNING

Do not flush the system through the
boiler.

For some old systems, there is a reluctance to
clean the piping because of possible leaks
occurring in badly corroded lines. Should the
customer refuse cleaning, it is necessary to
install filtration equipment. Install either a
fibrous filter or a centrifugal filter in the boiler
return piping. This will collect and remove
sediment from the system. A booster pump
may be required to overcome the additional
pressure drop introduced in the line by the
filter. When filling the system, provide
chemical treatment as outlined in Section 3.8.

Failure to properly clean the system or to
install mechanical sediment removal
equipment can result in tube blockage and
severe corrosion plus damage to pumps,
controls, and air removal devices.

Inspect, repair as necessary, or replace system
air control devices.

Install gauge glasses on air expansion tanks
and install a tank fitting in the system
connection to the tank.

Install a strainer in the boiler return piping.

3.7 Draining and refilling the boiler &

system

If the system is drained and then refilled,
chemical treatment is essential to treat the raw
water. Use only clean, softened water.

3.7.1 Filling The System

WARNING

Use only clean, softened, and treated
water. Chemical treatment of the raw
water is essential when filling or refilling
the system see section 3.8.

3.7.2 Hydrostatic Test Of Boilers And

System

After completing the boiler and burner
installation, the boiler connections, fittings,
attachments and adjacent piping must be
inspected for leaks by filling the unit with
water. The pressure should be gradually
increased to a pressure just below the setting
of boiler safety relief valve(s).

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Table 13: Chemical Agents and Effects

Compound

Effect

Calcium Carbonate,
(CaCO3)

Calcium Bicarbonate
(CaHCO3)

Soft scale,
CO2

Calcium Sulphate (CaSO4)

Hard Scale

Calcium Chloride (CaCl2)

Corrosion

Magnesium Carbonate
(MgCO3)

Magnesium Bicarbonate
(MgHCO4)

Corrosion,
Scale

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Remove the boiler tube access panels (see
dimensional drawing in the boiler manual).
Inspect the tube to header joints to be certain
that all tube fittings are sealed. This is
necessary because, although the boiler is
hydrostatically tested at the factory, minor
leaks in fittings and at attachments can
develop from shipping vibration or from
installation procedures. Replace tube access
panels before proceeding to start boiler.

3.8 Boiler Water Treatment

3.8.1 Purpose of water treatment

Water treatment is required for satisfactory
operation of the boiler. It must be devised to
prevent depositing of scale and corrosion
from acids, oxygen and other such harmful
elements that may be in the water supply. A
qualified water treatment chemist should be
consulted and the water systematically treated.

“Hot water systems must operate with a pH
above 8.5. A system that has a pH below 8.5

will usually develop the following problems:

1. Gas formation (air trouble)

2. Pump seal and gland problems

3. Air vents sticking and leaking

4. Frequent relief valve operating

5. Piping leaks at joints

4. Maintain the highest possible boiler fuel

efficiency.

5. Decrease the amount of boiler down

time from cleaning.

3.8.3 Water softener

It is highly recommended that a zeolite water
softener be used for all make-up to the boiler.
It is intended that this be used in addition to
the chemical treatment of the boiler. Water
softening removes calcium and magnesium,
the primary causes of hard boiler scale.

3.8.4 Continuous Monitoring

Water treatment should be checked and
maintained according to Table 14 whenever
the boiler is operating. The boiler operator
should be sure that the boiler is not operating
for long periods without proper water
treatment.

Water treatment may vary from season to
season or over a period of time. Therefore,
the water treatment procedure should be
checked not less than four times a year, and
possibly more frequently as the local water
conditions may indicate.

See Table 13 for examples of typical chemical
agents found in untreated water along with
their potential effects.

(American Boiler Manufacturers Association
[ABMA], 2005. Boiler Water Quality
Requirements and Associated Steam Quality
for Industrial / Commercial and Institutional
Boilers)”

3.8.2 Objectives

The basic objectives of water treatment are:

1. Prevent the accumulation of scale and

deposits in the boiler.

2. Remove dissolved gases from the water.

3. Protect the boiler against corrosion.

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Soft Scale

Soft Scale

Form: 2435

30

Magnesium Sulphate
(MgSO4)

Silicon Dioxide (SiO2)

Hard Scale

Dissolved Oxygen

< 0.007 ppm

Total Iron

≤ 0.1 ppm

Total Copper

≤ 0.05

≤ 9

ppm

≤ 0.5

grains/gal

pH

8.3 – 10.0

Nonvolatile TOC

< 1 ppm

Oily Matter

< 1 ppm

Revision: 9
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Corrosion

It should be noted that water boilers may well
need chemical treatment for the first filling
plus additional periodic chemical treatment,
depending on system water losses and the
makeup requirements.

All water introduced into the boiler should be
softened and should include an oxygen
scavenger like sodium sulfite. This is required
to remove dissolved oxygen from the water.
Dissolved oxygen will cause severe system
corrosion.

Total Hardness

WARNING

Chemicals used in treating boiler water
are toxic and/or harmful. Always use
protective clothing and equipment when
working with/near chemicals. Contact
local authorities to determine if treated
boiler water can be discharged into local
waste water system.

Table 14 Recommended Feed Water

Limits

CAUTION

Bryan Steam Standard Warranty does not
cover problems caused by oxygen
contamination of boiler water.

Bryan Steam Standard Warranty does not
cover problems caused by scale build-up.

When using Glycol products, all Glycol
manufacturers’ requirements, including
rust inhibitors, must be adhered. Max
50% Glycol.

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4 SYSTEM START-UP

WARNING

Completely read, understand and follow
all instructions in this manual, Concert
Boiler Control manual, and all other
component manuals supplied with this
boiler before attempting start- up.

4.1 Concert Boiler Control Display

Navigation

This boiler is equipped with a color touch
screen display, which presents information
and control options in a page manner. Pages
are arranged in a tree structure through which
the user navigates up and down to arrive at
the desired function. The page descriptions
and a complete list of the available control
parameters are provided in a separate
instruction manual for the Concert boiler
control (Also supplied with the boiler).

Most pages have a Home button in the
top-left corner of the screen. The Home
button returns the user to the Home page to
view real time operation of the boiler.

NOTICE

Refer to the Concert Boiler Control
manual for detailed instructions on the
use of the hydronic control and display.

4.2 System Check:

1. Verify that the venting, water piping, gas

piping and electrical system are installed
properly. Refer to installation instructions
contained in this manual.

2. Confirm all electrical, water and gas

supplies are turned off at the source and
the chimney/vent is clear of obstructions.
If boiler is controlled by an external
control system, this system must be
temporarily disconnected. The local
boiler controls should be allowed to
operate the boiler.

3. Confirm that all manual shut-off valves

between the boiler and gas supply are
closed.

4.3 Power the Boiler:

The back button returns the user to the
previous page.

A padlock icon will be shown on the
screens that require the user to enter a
password to change the parameter. An
unlocked padlock indicates the correct
password has been entered to change the
parameter.

The user can access the following icons from
the Home screen: Menu, Info, Status, Adjust,
and Help. It is important that the user
become familiar in accessing additional icons
that are not shown on the home screen page.

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Turn on the electrical supply to the boiler and
circulation system at fused disconnect switch.
Ensure that the circuit breaker switch is in the
“ON” position.

4.4 Power the Circulators:

Turn system circulators on and purge air from
the boiler and system piping.

4.5 Pressurize the Fuel System:

1. Open the manual gas shut-off valves

located upstream of the field supplied gas
regulator. Do not open manual gas valve
directly outside the boiler jacket.

2. Purge gas line of air.

3. Open manual ball valve outside boiler

jacket. Confirm that the supply pressure
to the manual ball valve tapping outside

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the boiler jacket conforms to Table 6 for
maximum and minimum supply pressure.

4. Repeat steps 2 and 3 for boiler gas train

components.

4.6 Boiler Commissioning:

All of the installation instructions found in
sections 1 through 3 shall be completed
before commissioning the boiler.

DANGER

Failure to properly adjust excess air will
result in unsafe levels of carbon
monoxide. Variations in venting or
combustion air pressure and temperature
will change excess air. Adjust excess air
levels so that variation in venting or
combustion air pressures and
temperatures caused by change of
seasons, wind conditions, opening or
closing of boiler room doors or windows
do not cause the boiler to operate with
carbon monoxide concentration above 400
parts per million.

1. Identify boiler water, gas, and electrical

connections, and other safety controls.

2. Locate manometer pressure taps for

pressure measurements in the following
areas:

a. Supply gas pressure (ball valve

tapping outside of boiler top jacket
panel)

b. Stack or flue outlet pressure

3. Install a gas analyzer probe within 6”

above the boiler flue gas outlet.

4. Verify the high temperature limit (auto

0

reset) is set to 200

5. Verify the high and low gas pressure

switch limits.

a. High gas pressure switch at 1.0” w.c.
b. Low gas pressure switch at 3.0” w.c.

F. (1000 only)

6. Menu > Operation > Auto / Manual

Rate Control > Manual (76 password
required)

7. Switch boiler circuit breaker in the

control panel to the ON Position (1000
only).

8. Close the manual gas valve between the

automatic gas valve and the blower
inlet.

9. Cycle the boiler. The boiler should

lockout on gas pressure failure. In this
case it should be the low gas pressure
switch.

10. Reset the low gas pressure switch and

gas pressure lockout.

11. Increase the high gas pressure switch

setting to 14” w.c.

12. Cycle the boiler. The boiler should

lockout on flame failure or ignition
failure. (Boiler may recycle once if there
was an ignition failure. Repeat step 12.)

13. Reset the flame failure lockout and

decrease the high gas pressure setting to
1” w.c.

14. Cycle the boiler. The boiler should

lockout on gas pressure. In this case it
will be the high gas pressure switch.

15. Open the manual gas valve between the

automatic gas valve and the blower
inlet.

16. Reset the high gas pressure switch and

gas pressure lockout.

17. Cycle the boiler. The boiler should

establish main flame.

18. If flame is not established reset the

flame failure lockout and repeat step 17.

(Consult with the factory for assistance
if flame cannot be established after 3
attempts.)

19. Check that O2 levels are within a safe

operating range. (4.5% to 7.0%)

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20. Menu > Operation > High/Low > High

> Back Arrow (76 password required)

21. Once boiler has reached high fire rate,

check that O2 levels are within a safe
operating range. (4.5% to 7.0%)

22. Adjust supply gas pressure between 4”

w.c. and 14” w.c. as measured at the ball
valve tapping outside of the boiler top
jacket panel.

23. Adjust the O

level so that it is within

2

4.5 to 7.0 % at high fire with all jacket
doors installed and front cabinet door
closed.

a. For best efficiency, standard O2

should be set to 4.5% to 4.6%.

b. For boilers specified to be less than

20ppm NOx adjust the O

level

2

within 6.5% to 7.0%.

c. For boilers specified to be less than

9ppm NOx adjust the O2 level within

7.0% to 9.0%.

Note: High Fire O

levels are adjusted with

2

the gas shutter valve located on the
outlet of the gas valve.

i. Turn adjustment screw toward the

‘Plus (+)’ side to increase gas flow
(decrease O

level).

2

ii. Turn adjustment screw toward the

‘Minus (-)’ side to decease gas flow
(increase O

level)

2

24. Menu > Operation > High/Low > Low

> Back Arrow (76 password required)

25. Verify the O

level is within +/- 0.3% of

2

the O2 level set at high fire with all
jacket doors installed and front cabinet
door closed. (Consult the factory for
assistance if the O2 levels are not within
+/- 0.3% from high fire to low fire.)

Warning

Improper adjustments to the low fire
offset adjustment can lead to rough light­offs and nuisance flame failures.

26. Verify O2 repeatability by

commanding the boiler to high fire
and low fire as many times as
required, repeating steps 20 to 26 as
necessary.

Figure 6: High Fire Adjustment on the

Main Gas Valve Regulator

27. Once the boiler is operating within

the specified high and low fire
ranges, record emissions, flue draft,
and other important data on the
installation and startup report, see
Appendix C.

28. Perform tests on each of the components

listed in Table 15.

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4.7 Finish Commissioning the Boiler:

Reconnect any wires from the external control
system, if applicable.

1. Perform an operation test of the external

control system.

2. Place system control back in normal

operation, if necessary.

3. Place the boiler into automatic mode.

Menu > Operation > Auto / Manual Rate
Control > Automatic (76 password
required)

4.8 Re-Starting After Prolonged

Shutdown

Use the following recommendations prior to
re-starting the heating system after prolonged
shutdown.

1. Perform Pre-Start-Up Inspection by

checking all gas, water, air intake and
venting connections to ensure proper,
leak-free connections and that the water
and gas lines has been cleaned
completely.

2. Ensure that combustion air piping, vent

piping, and terminations are free of
obstructions.

3. Inspect the boiler for damage and loose

wire connections.

4. Remove all flammable material present in

the vicinity of the boiler.

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Table 15: Safety Device Test

Component

Test Method(s)

After Lockout
Annunciation

Actual Alarm

Message

High Gas Pressure

Close the manual gas

Manually reset the

setting.

Hard Lockout.

Low Gas Pressure

Increase the setting of

Manually reset the

setting.

Hard Lockout.

Burner Thermal Fuse

Disconnect one wire of

Re-connect wiring to the

fuse lockout.

Hard Lockout

Blocked Condensate

Disconnect one wire of

Re-connect wiring to the

lockout.

Hard Lockout

Vestibule Thermal

Disconnect one wire of

Re-connect wiring to the

thermal fuse lockout.

Hard Lockout

Low Water Cutoff

With the boiler running

burner.

Manually reset the

Hard Lockout.

Auto Reset (High

With the boiler running

main burner.

Adjust the limit to its

High Limit Auto

Water Flow Switch

Reduce the water flow

boiler shuts down.

Adjust manual valve to

Low Water Flow

Revision: 9
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4.9 Testing of Controls and Safety Devices

Prior to placing the boiler in operation, the installing contractor or other responsible personnel must
perform safety and control device limit tests to ensure proper operation of the appliance. Refer to
Table 15 for recommended method(s) of carrying out these safety limit devices tests.

Switch

Switch

Switch

Fuse (1000 Only)

valve between the gas
valve and air inlet.
Cycle boiler.

the switch until the
switch trips.

the burner thermal
fuse. Cycle the boiler.

the blocked condensate
switch. Cycle the
boiler.

the vestibule thermal
fuse. Cycle the boiler.

Concert Boiler Control
and switch. Adjust the
switch to its normal

Concert Boiler Control
and switch. Adjust the
switch to its normal

burner thermal fuse.
Reset burner thermal

blocked condensate
switch. Reset blocked
condensate switch

blocked condensate
switch. Reset vestibule

Gas Pressure

Switch

Gas Pressure

Switch

Burner Thermal

Fuse

Blocked

Condensate

Switch

Vestibule Thermal

Fuse

push and hold the
LWCO test button
until the boiler control
shuts down the main

Temp) Limit (1000

only)

lower the setting of the
limit so that the boiler
control shuts down the

rate with a manual
shutoff valve until the

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Concert Boiler Control
and reset the LWCO.

normal setting.

normal position.

Low Water Level

Reset

Form: 2435

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4.10 Ignition Failure

After the first ignition failure, the boiler goes into a hard lockout and a manual reset of the Concert
Boiler Control is required to restart the boiler. The boiler will then attempt to light off after it has
completed its post-purge process.

DANGER

Contact the boiler manufacturer or a qualified heating service technician if the boiler has
failed to light consecutively three times after initially resetting the Concert boiler control.

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5 Service, Maintenance, and Inspection

5.1 General Maintenance:

1. Follow any checks and/or inspections that

may be required as specified in the
component manufacturers’ instruction
manuals.

2. Repair or replace any defective

components immediately.

3. The following service procedures are

required for proper and safe boiler
operation.

DANGER

This boiler uses flammable gas, high
voltage electricity, moving parts, and very
hot water under high pressure. Assure that
all gas and electric power supplies are off
and that the water temperature is cool
before attempting any disassembly or
service.

More than one gas shut-off valve and
electrical disconnect switch are used on
the boiler. Assure that all gas valves and
electrical disconnect switches are off
before attempting any disassembly or
service.

Do not attempt any service work if gas is
present in the air in the vicinity of the
boiler. Never modify, removed or tamper
with any control device.

Do not use matches, candles, open flames
or other ignition source to check for leaks.

Read, understand and follow all the
instructions and warnings contained in all
the sections of this manual. The
instructions and warnings contained in all
of the component instruction manuals.

If any electrical wires are disconnected
during service, clearly label the wire and
ensure that the wires are reconnected
properly.

Never jump out or bypass any safety or
operating control or components of this
boiler.

Assure that all safety and operating
controls and components are operating
properly before placing boiler back in
service.

WARNING

The service instructions contained in this
manual are in addition to the instructions
provided by the manufacturer of the boiler
components. Follow component
manufacturer’s instructions. Component
manufacturer’s instructions were provided
with the boiler. Contact component
manufacturer or Bryan Steam for
replacement if instructions are missing.
Do not install, start up, operate, maintain
or service this boiler without reading and
understanding all of the component
instructions. Do not allow the boiler to
operate with altered, disconnected or
jumpered components. Only use
replacement components identical to
those originally supplied by Bryan Steam.

WARNING

This boiler must be serviced and repaired
by skilled and experienced service
technicians only.

If any controls are replaced, they must be
replaced with identical models supplied
by Bryan Steam.

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All cover plates, enclosures, and guards
must be in place at all times, except
during maintenance and servicing.

5.1.1 DAILY:

1. Make visual inspection of gauges,

monitors, and indicators and record
readings in boiler log.

Form: 2435

38

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

2. Make visual check of instrument and

equipment settings against factory
recommended specifications.

2. If inspection of the boiler tube surfaces

reveals a build-up of soot (carbon), the
tube surfaces should be thoroughly
brushed. Failure to do so may result in

3. Check operation of probe type low water

cutoff(s) to ensure control is functioning.

4. Check gas train for gas leaks and water

piping for any leaks.

5. Confirm boiler area is free of combustible

materials and that there is nothing

reduced efficiency, fire and asphyxiation
hazards.

3. The boiler pressure vessel and piping

should be checked annually.

4. Inspect the ignition rod for carbon build

up.

obstructing air intake and vent.

5. Inspect lens of the ultra-violet (uv)

scanner and remove any debris with soft

5.1.2 WEEKLY:

cloth and make sure that hole is clear
from scanner to burner.

1. Check combustion safety controls for

flame failure (or other alarm messages).

2. Check all limit controls and low water

cutoff as described above.

3. Check condensate drains for any

obstructions.

4. Check carbon monoxide level in flue

products.

6. Replace air filter.

5.2 Ignition Assembly Cleaning

1. Disconnect power and shut off the

external manual gas valve to the boiler
prior to removing the ignition assembly.

2. When removing the igniter, extra

caution must be taken to prevent

5.1.3 MONTHLY:

damaging the ceramic insulator.

1. Check high and low gas pressure

interlocks. Refer to manufacturer's
instructions for correct procedure.

2. Check proper operation of safety relief

valve.

3. Check water quality and correct if needed.

4. Inspect boiler air filter.

5.1.4 ANNUALLY:

1. The flue gas passages and the exterior

surfaces of the boiler tubes should be
inspected at least once annually. Any
accumulation of soot or debris should be
thoroughly cleaned out.

3. Remove any excess oxide deposits from

the surface of the igniter with steel wool
or emery cloth. Do not use sandpaper.

4. Inspect the ceramic insulator for cracks,

and if necessary, replace the igniter.
After each inspection of the igniter,
replace gasket and apply anti-seize
compound to mounting screws prior to
reinstalling them.

5. Ensure that igniter electrode spacing is

within 1/8 inch.

6. When reinstalling the igniter after

inspecting it, make sure there is a ⅜inch
gap between the igniter and the burner
surface.

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3. Be careful not to damage or disturb the

insulation inside of the heat exchanger.

Figure 7: Ignition Assembly

• 1. Igniter

• 2. Ultra-Violet (UV) Scanner

• 3. ½” Heat Insulator

• Igniter Gasket

5.3 Burner Assembly Cleaning

1. After disconnecting power to the boiler,

remove the boiler’s furnace door. For
part identification, refer to the “Repair
Parts” section of this manual.

2. Clean around the burner assembly by

blowing compressed air over the surface
of the burner to remove lint and debris
accumulation. Be careful when cleaning
the burner assembly, to avoid damaging
the metal mesh burner surface.

3. If the burner or the burner gasket shows

any visual deterioration or corrosion
signs, replace it immediately.

4. After replacing the burner or burner

gaskets, check for proper operation by
performing combustion analysis, as well
as checking for gas leakage around the
burner mounting and blower transition
pieces.

5.4 Heat Exchanger Cleaning

1. Perform visual inspection of both boiler

flue passes, and remove any debris from
the surfaces of the heat exchanger.

2. If necessary, brush the tubes of the heat

exchanger using non-abrasive, non­metallic bristle brush.

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5.5 Tube Replacement Procedure

NOTICE

Performing a regular boiler inspection will prolong the life of the heat exchanger, and
ensure optimal function and energy efficiency. For best practices, adhere to the general
guidelines outlined in the service and maintenance section of this manual.

1. Inspect the boiler. Use the following steps to identify a potential tube leak and to minimize

possible damage to the boiler and other equipment as a result of tube failures.

a. Shut off power to the boiler immediately from the external, dedicated electrical disconnect.
b. Confirm that any water leakage is not the result of a blocked condensate drain line.
c. Confirm that any water leakage is not the result of a blocked condensate drain line.
d. Remove the boiler’s left side jacket panels and flue collector access panels as shown in

Figure 8.

e. Visually inspect the burner and furnace pass insulation for water damage. If significant water

damage to the insulation or burner is observed, contact the manufacturer.

f. Identify any leaking tubes.
g. Isolate and drain the boiler completely.

2. Use the proper tools. Use the following tools to remove and replace leaking boiler tubes:

a. Tube Puller (P/N 106019-02)
b. Tube Driver (P/N 106019-01)
c. Sledgehammer (steel head, approximately 3 lb)

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Figure 8: Panel Removal in Preparation for Tube Inspection

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1. Loosen tube-ends. Insert tube puller between the tube-end and header. Apply pressure to the

puller and strike the side of the tube two or three times with a hammer to help loosen the tube­end in the upper and lower header.

2. Pull lower tube end. Wedge the tube puller under the flange of the tube. Drive the tube puller

with several blows with a hammer on the end of the handle. Alternate with downward blows to
lift tube-end.

3. Clear tube-end from the header. Continue driving wedge under and leveraging flange up until it

pops the end of the tube free from the hole in the header.

4. Pull upper tube-end. Repeat the procedure to the pull the tube-end of the same tube from the

upper header.

5. Prepare the headers and replacement tubes. Before placing a new tube into the header, clean

the holes by wiping gently with emery cloth to be sure that there are no burrs. Clean the
replacement tube-ends of any rust or debris. With a small brush, apply a thin coating of gray
pipe dope around the inside of the hole. Pipe dope may also be applied to the tube-end. Cutting
oil may be mixed with the pipe dope for easier application.

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Figure 9: Tube Puller Insertion

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6. Insert both ends of the tubes into the headers. Insert the lower tube-end into the bottom

header first. Then insert the top tube-end into the top header. Insert all replacement tubes
before driving them.

7. Drive the upper and lower tube-ends. DO NOT drive the tube-ends down to the flange. With

the driver tool positioned on the flange, strike the end of the driver with hammer. After a few
hits, the feel of the strike will become solid. The tone will also change from a “ting” sound to
more of a “tong” sound. This indicates the tube has seated.

CAUTION

Do Not Overdrive Tubes! Overdriving tubes can cause damage to the tubes and boiler
header holes. Use only approved Bryan Steam tube driver and specified hammer. The end­formed tube fitting is designed to deform if overdriven to minimize damage to the vessel
tube holes.

8. Reinstall the tube clamps. Replace the nuts and flat washers if damaged in any way. Use brass

nuts only! Tighten the nuts until snug. Do not try to compress the tube-ends into the holes with
the clamps, because the clamps might break or the stud might shear.

9. Refill the boiler. Fill the unit with water and ensure that there is no leakage at the replacement

tube-ends before reinstalling the flue collector panels.

WARNING

If a leak is detected after a replacement tube has been installed, pressure in the boiler must
be reduced to zero before adjusting tube(s). Adjusting tubes under pressure could result in
serious personal injury.

10. Reinstall all flue access doors, door clamps, and jacket panels.

11. Perform startup check prior to putting boiler back into operation.

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Table 16: Safety and Operating Controls

Component

Function

If this switch is in the off position, power is interrupted to the control circuit of the boiler,

supplied to the control circuit.

Automatic

Aquastat

If the boiler water temperature exceeds the adjustable set point, power is interrupted to the

supplied to the control circuit.

If the boiler water temperature exceeds the adjustable set point, power is interrupted to the

temperature has dropped below the setpoint minus the differential setting.

If the water flow through the boiler drops below the fixed flow rate required to move the

paddle closes the control’s contacts and power is supplied to the control circuit.

Pressure /

Valve

If the pressure inside the boiler exceeds the fixed set point, the valve opens mechanically and

If the gas pressure reaches a point above or below the adjustable set point, the contacts of

switches will not reset until the gas pressure is within the set point parameters.

Minimum

Switch

If the differential air pressure drops below the fixed set point, the contacts of the switch open

Maximum

Switch

If the differential air pressure exceeds the fixed set point, the contacts of the switch open and

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

5.6 Safety and Operating Controls

All of the safety control devices listed in Table 16 are logically linked to the Concert Boiler Control
that supervises the sequence of operation of the boiler for safe and efficient operation. It does so by
ensuring proper light off and firing of the main burner and if need be, will immediately cut-off gas
supply to the main burner when gas pressure, water temperature, water flow or another critical
attribute is outside of the operational settings. It also varies the combustion rate in real time to meet
the desired load of the system.

WARNING

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 should
refer to those who have completed Bryan Steam Service School training specific to this
product.

Power
Switch

Reset

Operating

Manual

Reset High

Limit

Aquastat

Water Flow

Switch

Safety Relief

High and

Low Gas

Pressure

Switches

which prevents the boiler from operating. If the switch is in the on position, power is

control circuit of the boiler, which prevents the boiler from operating. When the boiler water
temperature drops below the set point minus the adjustable differential setting, power is again

control circuit of the boiler, which prevents the boiler from operating. Power is interrupted
until the control is manually reset pressing the control’s reset button. When the button is
pressed, power will again be supplied to the control circuit, assuming that the boiler water

control’s paddle enough to close the control’s contacts, power is interrupted to the control
circuit, which prevents the boiler from operating. When the water flow rate increased, the

discharges water. The valve remains open until the pressure inside the boiler drops below the
set point.

the switch open and power is interrupted to the control circuit that prevents the boiler from
operating. Power is interrupted until gas pressure is between the high and low gas pressure
set points and the control is manually reset moving the switch to the reset position. The

Air Pressure

Air Pressure

and power is interrupted to the control circuit, which prevents the boiler from operating.
Power is interrupted until air flow/pressure increases so that contacts close.

power is interrupted to the control circuit, which prevents the boiler from operating. Power
is interrupted until air flow/pressure decreases below the setting so that the contacts close.

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Table 17: General Troubleshooting

INDICATION

POSSIBLE CAUSE

CORRECTIVE ACTION

Boiler is not
responding to a call

“Priority” show
“Standby”.

Boiler is not seeing
Enable/Disable of
Domestic Demand
Input.

Check wiring for loose connections or wiring
errors. If Domestic Demand is expected check
the DHW Demand/Modulation is selected
properly.

Boiler is not
responding to call for

Central Heat or
Domestic Hot Water.

Check wiring for loose connections or wiring
errors.

Request the system and boiler pumps will be
free to run.

Display Completely
Dark Fun off, LWCO

power light on
Control.

No 120 Vac Power at
Boiler due to blown
high voltage fuse or
circuit breaker trip.

Check breaker and wiring between breaker and
boiler.
Replace blown high voltage fuse.
Reset tripped breaker.

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

5.7 Troubleshooting

Refer to the troubleshooting section in the Concert Boiler Control manual on how to navigate the
Limit String Status screen that shows an active safety limit status and for an in-depth guide to all the
possible lockouts as well as recommended corrective actions for restore boiler operation.

for heat, “Status” and

heat, “Status” shows
“Standby” and
“Priority” shows

Boiler is Running but
System or Boiler
Circulator is not
running.

Boiler is not firing, or
temperature is greater
than setpoint.

Pump Not Running.

Select display Help icon and review Limit
String Status.

When there is a Domestic Hot Water Heat
Request the System or Boiler Pump will be
forced “off” when their “Run Pump for”
parameter is set to “Central heat, off DHW
demand” or “Central Heat, Optional Priority”.
This has been set to allow all of the heat to be
provided for fast indirect water heater
recovery. After “Priority protection” time or
the end of the Domestic Hot Water Heat

lights off, no green

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Table 17: General Troubleshooting

INDICATION

POSSIBLE CAUSE

CORRECTIVE ACTION

Check loose 120 Vac connection wiring
between boiler J-Box and transformer or 24

Check for bad transformer or bad 24 Vdc
power supply: Replace if necessary.

The green light is connected to internal power
supply. The power supply is repeatedly

light. When the faulty wiring reconnected,
green light will begin to flash.

Blank Screen with
“Reading” shown.

Display lost
communication with
Control.

Failure to establish Communication upon boot­up once you establish communication, reboot
display to read controller and setup display
properly.

Communication Error
2

Un-configured control,
or control has a
memory failure.

The display-write attempt has failed. The
controller is un-configured or has a memory
failure. Lockout 20 Safety Data Verification will
also be displayed. Replace Control.

Display has lost communication with
controller.

Refer to Concert Boiler Control manual for
more details.

Short Cycling

Oversized Boiler

Examine system and boiler operational settings
to determine what adjustments may be made
to reduce boiler cycling.
Contact Manufacturer.

Incorrect Gas Valve
Settings

If combustion is too lean or rich as a result of
improper gas valve settings, adjust air-fuel
ratio to match factory O2 settings.

Inspect heat exchanger tubes for damage and
carbon build-up. Inspect and clean the burner

and Inspection section of the manual for
guidance.

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Vdc power supply.

Display Completely
Dar, Fun running.

Blinking Green power
light on Control.

No 120 Vac Power at
Control; No 24 Vdc to
Display.

Control Fault.

Check for loose 24 Vac connection wiring
between transformer and Control.
Check blown low voltage fuse: Replace in
necessary.

starting and stopping (not normal) making the
light flash. The microprocessors are not
running. Try disconnecting all terminals
except 24 Vac to power the control. The green
light should be steady. If it is not, then the
control is defective. If steady, start plugging in
all the connectors while watching the green

Communication Error
3

Communication Fault.

Poor Combustion Dirty Heat Exchanger

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Check for loose or defective display harness,
defective display or defective control.

assembly. Refer to the Service, Maintenance

Form: 2435

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Table 17: General Troubleshooting

INDICATION

POSSIBLE CAUSE

CORRECTIVE ACTION

Leakage

Remove the boiler’s side panels and check for
flue gas leakage around the heat exchanger,
burner mounting plate, and blower transition
piece.

Revision: 9
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Table 18: Maximum Gas Capacity Of Schedule 40 Pipe

Pipe
Length in
Equivalent
Feet

Pipe Size (nps)

¾ 1 1-1/4

1-1/2

2 2-1/2

3

4
10

273

514

1060

1580

3050

4860

8580

17500

20

188

353

726

1090

2090

3340

5900

12000

30

151

284

583

873

1680

2680

4740

9660

40

129

243

499

747

1440

2290

4050

8270

50

114

215

442

662

1280

2030

3590

7330

60

104

195

400

600

1160

1840

3260

6640

70

95

179

368

552

1060

1690

3000

6110

80

89

167

343

514

989

1580

2790

5680

90

83

157

322

482

928

1480

2610

5330

100

79

148

304

455

877

1400

2470

5040

125

70

131

269

403

777

1240

2190

4460

150

63

119

244

366

704

1120

1980

4050

175

58

109

224

336

648

1030

1820

3720

200

54

102

209

313

602

960

1700

3460

Based on gas pressures less than 2 psig and a pressure drop of 3.0 iwc and 0.6 specific gravity.

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Appendix A Sizing Gas Piping

Design the gas piping system to provide an adequate gas supply to the boiler. Refer to Table 6 for
minimum and maximum gas supply pressures and boiler capacities. Also consider existing and
expected future gas utilizing equipment (i.e., water heater, cooling equipment). Refer to Table 18 for
maximum capacity of schedule 40 pipe. Table 19 lists equivalent pipe length for standard fittings.
Given the specific gravity of gas at the boiler’s location, a correction factor can be found on Table
20 and multiplied by the “Capacity in Cubic Feet of Gas Per Hour” on Table 18. For gas piping
material other than schedule 40 pipes, refer to the National Fuel Gas Code, NFPA 54/ANZI
Z223.1 and/or CAN/CGA B149 Installation codes. Use methods and materials in accordance with
Local Codes and requirements of gas supplier. In the absence of such requirement follow National
Fuel Gas Codes, NFPA /ANSI Z 223.1 and/or CAN/CGA B149 Installation Codes.

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Table 19: Equivalent Lengths Of Standard Pipe Fittings And Valves

Valves Fully Open (Screwed, Flanged,
Welded)

Schedule 40, Screwed Fittings

Swing
Check

90 deg.

(threaded)

45 deg.

(threaded)

90 deg.
Tee, Flow

Branch
(threaded)

1/2

.622

.36

17.3

8.65

4.32

1.55

.73

3.1

3/4

.824

.48

22.9

11.4

5.72

2.06

.96

4.12

1

1.049

.61

29.1

14.6

7.27

2.62

1.22

5.24

1-1/4

1.38

.81

38.3

19.1

9.58

3.45

1.61

6.9

1-1/2

1.61

.94

44.7

22.4

11.2

4.02

1.88

8.04

2

2.067

1.21

57.4

28.7

14.4

5.17

2.41

10.3

2-1/2

2.469

1.44

68.5

34.36

17.1

6.16

2.88

12.3

3

3.068

1.79

85.2

42.6

21.3

7.67

3.58

15.3

4

4.026

2.35

112

56

28

10.1

4.7

20.2

6

6.065

3.54

168

84.1

42.1

15.2

7.07

30.4

Equivalent lengths are for standard screwed fittings and for screwed, flanged, and welded valves
relative to schedule 40 steel.

Table 20: Specific Gravity Correction Factors

Specific Gravity

Correction Factor

Specific Gravity

Correction Factor

.5

1.1

1.2

.71

.55

1.04

1.3

.68

.6

1.0

1.4

.66

.65

.96

Propane

.7

.93

1.5

.63

.75

.9

1.6

.61

.8

.87

1.7

.59

.85

.84

1.8

.58

.9

.82

1.9

.56

1.0

.78

Butane

1.1

.74

2.0

.55

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Pipe
Size
(nps)

ID
(in.)

Gate Globe Angle

Elbow

Elbow

Through

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FF1000 Pressure Drop in Equivalent Feet (Flue Vent)

Flue Vent

Diameter (in.)

Straight Length

(eq ft/ft)

90° Elbow

(eq ft)

45° Elbow

(eq ft)

Velocity

(fpm)

6 1 10

5

1534

8

.22

2.22

1.11

863

FF1500 Pressure Drop in Equivalent Feet (Flue Vent)

8

.56

5.88

2.86

1296

10

.174

1.75

.87

829

FF2000 Pressure Drop in Equivalent Feet (Flue Vent)

8 1 10

5

1728

10

.31

3.125

1.56

1106

12

.12

1.19

.59

768

FF2500 Pressure Drop in Equivalent Feet (Flue Vent)

8

1.563

16.67

8.33

2158

10

.478

5

2.44

1381

12

.183

1.852

.92

959

FF3000 Pressure Drop in Equivalent Feet (Flue Vent)

8

2.22

25

11.11

2591

10

.68

7.14

3.57

1650

12

.267

2.7

1.35

1152

FF1000 Pressure Drop in Equivalent Feet (Combustion Air Duct)

Air Duct

Diameter (in.)

Straight Length

(eq ft/ft)

90° Elbow

(eq ft)

45° Elbow

(eq ft)

Velocity

(fpm)

6

.6

6.25

3.13

1121

8

.13

1.32

.658

631

FF1500 Pressure Drop in Equivalent Feet (Combustion Air Duct)

8

.3

3.03

1.49

946

10

.09

.92

.46

605

FF2000 Pressure Drop in Equivalent Feet (Combustion Air Duct)

8

.53

5.26

2.63

1264

10

.164

1.64

.82

809

12

.063

.63

.314

562

FF2500 Pressure Drop in Equivalent Feet (Combustion Air Duct)

8

.83

8.3

4.17

1576

10

.26

2.56

1.28

1009

12

.1

.98

.49

701

FF3000 Pressure Drop in Equivalent Feet (Combustion Air Duct)

8

1.19

12.5

5.9

1895

10

.37

3.7

1.85

1213

12

.14

1.41

.7

842

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Appendix B Vent and Combustion Air Pressure Drop Data

The combined pressure drop through the vent and combustion air duct shall not exceed 100
equivalent feet. Use the tab l es below to calculate the pressure drop in the vent / combustion
air system.

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Appendix C Installation & Startup Report

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Appendix D Venting Diagrams

Appendix D.1 Typical Horizontal Vent Piping

Form: 2435

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Appendix D.2 Typical Vertical Pressurized Venting

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Appendix E Combustion Air Diagrams

Appendix E.1 Typical Horizontal Air Intake Piping

Form: 2435

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Free Flex Installation and Operation Manual Date: 9-1-2017

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Phone: [phone] Fax: [phone] Email: [e-mail]

55

Appendix E.2 Typical Vertical Air Intake Piping

Form: 2435

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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Phone: [phone] Fax: [phone] Email: [e-mail]

56

Appendix F Boiler Piping Diagrams

Appendix F.1 Single Boiler, Primary / Secondary

Form: 2435

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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Phone: [phone] Fax: [phone] Email: [e-mail]

57

Appendix F.2 Multiple Boilers, Primary Reverse-Return Piping

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]

58

Appendix F.3 Multiple Boilers, Primary / Secondary Reverse Return Piping

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]

59

Appendix F.4 Multiple Boilers, Primary / Secondary Piping

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]

60

Appendix F.5 Multiple Boilers, Primary / Secondary Piping, Heating with Domestic Hot Water

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]

61

Appendix F.6 Multiple Boilers, Primary / Secondary Piping, Heating with Domestic Hot Water (continued)

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]

62

Appendix G Water Flow Pressure Drops

Delta T’s are based on the maximum output with a nominal boiler efficiency of 95%.

FREE FLEX 1000

FREE FLEX 1500

FREE FLEX 2000

Delta T

GPM

Ft. Hd.

Delta T

GPM

Ft. Hd.

Delta T

GPM

Ft. Hd.

100F

19

0.51

100F

29

0.37

100F

38

0.65

90F

21

0.63

90F

32

0.45

90F

42

0.80

80F

24

0.79

80F

36

0.58

80F

48

1.02

70F

27

1.04

70F

41

0.75

70F

54

1.33

60F

32

1.41

60F

48

1.02

60F

63

1.81

50F

38

2.03

50F

57

1.47

50F

76

2.61

45F

42

2.51

45F

63

1.82

45F

84

3.22

40F

48

3.18

40F

71

2.30

40F

95

4.08

35F

54

4.15

35F

81

3.00

35F

109

5.32

30F

63

5.64

30F

95

4.09

30F

127

7.24

25F

76

8.13

25F

114

5.89

25F

152

10.43

20F

95

12.70

20F

143

9.20

20F

190

16.30

FREE FLEX 2500

FREE FLEX 3000

Delta T

GPM

Ft. Hd.

Delta T

GPM

Ft. Hd.

100F

48

0.80

100F

57

1.15

90F

53

0.99

90F

63

1.42 80F

59

1.25

80F

71

1.79

70F

68

1.63

70F

81

2.34

60F

79

2.22

60F

95

3.19

50F

95

3.20

50F

114

4.59 45F

106

3.95

45F

127

5.67

40F

119

5.00

40F

143

7.18

35F

136

6.53

35F

163

9.37

30F

158

8.89

30F

190

12.76

25F

190

12.80

25F

228

18.37

20F

238

20.00

20F

285

28.70

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

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63

Appendix H Wiring Diagrams

Appendix H.1 FF1000 Wiring Diagram

Form: 2435

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

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64

Wiring diagrams are for reference only, please refer to the wiring shipped with the boiler for accuracy.

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]

65

Appendix H.2 FF1500 To FF3000 115 VAC Single Phase Wiring Diagram

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

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66

Appendix H.3 FF1500 To FF3000 208 – 230 VAC Single Phase Wiring Diagram

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

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67

Wiring diagrams are for reference only, please refer to the wiring shipped with the boiler for accuracy.

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]

68

Appendix H.4 FF2000 To FF3000 208-460 VAC Three Phase Wiring Diagram

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]

69

Wiring diagrams are for reference only, please refer to the wiring shipped with the boiler for accuracy.

Form: 2435

70

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Appendix I Repair Parts

All boiler Repair Parts may be obtained through your local authorized Bryan Steam Representative.
Should you require assistance in locating a Bryan Steam representative in your area, or have
questions regarding the availability of Bryan Steam products or repair parts, please contact Bryan
Steam Customer Service at (717)-239-7642 or Fax [phone].

Appendix I.1 FF1000 Heat Exchanger

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

71

Table 21: Heat Exchanger Parts

Item
Numbe
r

Description

Quantity

Part Number

1

Lower Header

1

105670-01

2

Upper Header

1

105669-01

3

Convection Tubes Long Return (Yellow Paint)

9

105696-01

Convection Tubes Short Return (Black Paint)

9

105696-04

4

Furnace Tubes Long Return

9

105696-02

Furnace Tubes Short Return

9

105696-03

5

Convection Tube Access Door

1

(1) 105276-06

6

Furnace Tube Access Door

1

(1) 105539-01

7

Flue Collector Rear Panel

1

(1) 105277-01

8

Flue Collector Front Panel

1

(1) 105538-01

9

Flue Collector Side Panel

1

(1) 105540-01

10

Flue Collector Center Panel

1

(1) 105537-01

11

Flue Collector Top Panel

1

(1) 105541-01

12

Condensate Pan

1

(1) 105260-01

13

Horz. Convection tube Access Door Clamp

2

(2) 105263-01

14

Horz. Furnace Tube Access Door Clamp

2

(2) 105262-01

15

Vert. Tube Access Door Clamp

3

(3) 105261-01

16

Bottom Reinforcement Plate

1

(1) 105281-01

17

Vertical Center Reinforcement Plate

1

(1) 105284-01

18

Vertical Side Reinforcement Plates

2

(2) 105283-01

19

Top Reinforcement Plate

1

(1) 105282-01

20

Boiler Base Assembly

1

(1) T40010

21

Top Vestibule Panel

1

(1) 105343-01

22

Bottom Vestibule Panel

1

(1) 105343-02

23

E-Z Tab Stack Adapter

1

811EVC006

24

Center Panel Brace

1

(1) 105264-01

Not
Shown

Black Impregnated Gasket 2-1/2” Wide
(Tube Access Doors)

20.5 ft

(20.5 LF) 105668-02

Not
Shown

Black Impregnated Gasket 1” Wide
(Flue Collector)

37 ft

(37 LF) 102178-01

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

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Form: 2435

72

Table 22: Burner Assembly

Item

Number

Description

Quantity

Part Number
1

Ultra-Violet (UV) Scanner

1

106684-01

2

Heat Insulator

1

8026217

3

Ultra-Violet (UV) Lens Gasket

2

107031-01

4

Ultra-Violet (UV) Scanner Bracket

1

106685-01

5

Igniter/Scanner Gasket

1

105246-02

6

Burner

1

105618-01

7

Ultra-Violet (UV) Lens

1

107032-01

8

Igniter

1

105678-01

9

Site Glass Bushing

1

105657-01

10

Site Glass Gasket

2

105490-01

11

Site Glass Lens

1

105656-01

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Appendix I.2 FF1000 Burner Assembly

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

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Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Appendix I.3 Gas Train and Upper Vestibule Controls

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

74

Table 23: Gas Train and Upper Vestibule Controls

Key
No.

Description

(Quantity) Part
Number

3A

Blower

(1) 105326-01

3B

Swirl Plate

(1) 105327-01

3C

Manual Shut-Off Ball Valve

(1) 105325-01

3D

Main Gas Valve

(1) 105330-01

3E

High Gas Pressure Switch

(1) 105328-01

3F

Low Gas Pressure Switch

(1) 105329-01

3G

Ball Valve, 1-1/8" Tapping

(1) 105324-01

3H

Blower Adapter

(1) 105259-01

3I

1/4"NPT Plug

(2) 806603599

3J

1/4"NPTx1/4" Tube Compression
Fitting

(2) 822658
3K

Pressure Switch Tubing

(3FT) 92465560

3L

Minimum Air Pressure Switch
(Combustion Air)

(1) 106239-01

3M

Maximum Air Pressure Switch
(Blocked Vent)

(1) 105691-01
3N

Auto-Reset High Limit

(1) 80160626

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]

Form: 2435

75

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Appendix I.4 Jacket

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

76

Table 24: Jacket

Key
No.

Description

(Quantity) Part
Number

4A

Base

(1) 105124-01

4B

Front Left
Corner

(1) 105172-01

4C

Front Right
Corner

(1) 105172-04
4D

Center Rail

(1) 105176-01

4E

Hinges

(2) 105714-01

4F

Front Lower
Panel

(1) 105177-01
4G

Front Door

(1) 105170-04

4H

Front Upper
Panel

(1) 105169-01
4J

Top Panel

(1) 105174-04

4K

Rear Panel

(1) 105173-02

4L

Side Door

(1) 105178-02

4M

Air Intake Filter

(1) 811SOL0020

Not
Shown

Black Strip
Gasket

(67.5 LF) 105476-01

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]

Form: 2435

77

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Appendix I.5 Outlet Manifold

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

78

Table 25: Outlet Manifold

Key
No.

Description

(Quantity) Part Number

30 PSI
RV
Setting

50 PSI
RV
Setting

60 PSI
RV
Setting

75 PSI
RV
Setting

100 PSI
RV
Setting

125 PSI
RV
Setting

150 PSI
RV
Setting

5A

Upper Water
Outlet Manifold

(1) 105381-01

5B

Top Panel Water
Outlet Manifold

(1) 105382-01

5C

3" Victaulic
Coupling

(3) 104035-02
5D

1/2"NPT Air Vent

(1) 102260-01

5E

Temperature/Pre
ssure Gauge

(1) 103470-01

(1) 103470-02

(1)
103470

-03

5F

Pressure Relief
Valve

(1)
81660
338

(1)
816603
59

(1)
816603
75

(1)
816603
74

(1)
816603
77

(1)
816603
73

(1)
816603
78

5G

3" Cap

(1) 104035-03

5H

LWCO Probe

(1) 80160592

5I

Immersion Well
For Auto-Reset
High Limit

(1) 105684-01

5J

Brass Immersion
Well, Outlet Water
Sensor (10Kohm)

(1) 105684-01, (1) 105686-01
5K

Manifold Cover
Left Side Assy.

(1) 105480-02

5L

Manifold Cover
Cap Assy.

(1) 105480-03

5M

Manifold Cover
Right Side Assy.

(1) 105480-01

N/A

Optional Remote
Header sensor,
Immersion Well

(1) 105685-01, 105684-01

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]

Form: 2435

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Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Appendix I.6 Miscellaneous External Components

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

80

Table 26: Miscellaneous External Components

Key
No.

Description

(Quantity) Part Number

6A

Lower Rear Manifold

(1) 105384-01

6B

Water Inlet Manifold

(1) 105383-01

6C

Exhaust Stack

(1) 105697-01

6D

Condensate Trap

(1) 105432-01

6E

3" Victaulic Coupling

(3) 104035-02

6F

3" Cap

(1) 104035-03

6G

Water Inlet/Outlet Manifold Trim Ring and Gasket

(3) 105211-02, (3) 8205644

6H Vent Outlet Trim Ring and Gasket

(1) 105211-01, (1) 105486­01

6J

J-box and J-box Cover

(1) 8136056, (1) 8136027

6K

Water Flow Switch

(1) 105687-01

6L Brass Immersion Well, Inlet Temperature Sensor 10Kohm

(1) 105684-01, (1) 105685­01

6M St Steel Immersion Well, Stack Temperature Sensor

(1) 105683-01, (1) 105686­01

6N

1" Pipe Trim Ring and Gasket

(2) 105211-04, (2) 8205652

6O Air Vent Trim Ring and Gasket

(1) 105211-05, (1) 105693­01

6P

Air Intake Ring and Gasket

(1) 81156106, (1) 82056106

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]

Form: 2435

81

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Appendix I.7 Controls

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

Form: 2435

82

Table 27: Controls

Key No.

Description

(Quantity) Part Number

7A

Control Panel

(1) 105171-01

7B

Concert Boiler Control

(1) 105681-01

7C

24VDC Transformer

(1) 105680-01

7D

120/24V Step-down Transformer

(1) 801600502

7E

Low Water Cut-Off Reset Box

(1) 80160591

7F

Display

(1) 105682-01

7G

On/Off Switch

(1) 105658-01

7H

Ignition Transformer

(1) 80160208

7J

Ignition Cable

(1) 105218-01

7K

Blocked Condensate Switch

(1) 105659-01

Not Shown

Control-Limit-Power Harness

(1) 105660-01

Not Shown

Communication-Sensing Harness

(1) 105661-01

Not Shown

Line-Flow Harness

(1) 105662-01

Not Shown

Display Power Harness

(1) 105663-01

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]

Form: 2435

83

Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

Bryan Steam

(“seller”)

LIMITED WARRANTY

LIFETIME THERMAL SHOCK WARRANTY

Subject to the terms and conditions herein, Seller
warrants to the original owner at the original
installation site that the boiler pressure vessel is
covered against failure due to “Thermal Shock” for the
lifetime of the boiler as described below:

• This warranty is only valid if the boiler is installed

and operated in accordance with our Installation
and Operation Manual.

• This warranty shall cover leaks in pressure vessel

(boiler tubes, upper and lower drums) when upon
inspection by seller, such damage is attributed to
unequal expansion, often described as “thermal
shock.”

• This warranty does not cover damages or failures

that can be attributed to corrosion, scale, dirt or
sludge accumulation in the boiler, low water
conditions, failure of any safety devices or any
other improper service, operation or neglect.

LIFETIME PRESSURE VESSEL WARRANTY

Subject to the terms and conditions herein, Seller
warrants to the original owner at the original
installation site that the boiler pressure vessel is
covered against leaks (boiler tubes, upper and lower
drums) for the lifetime of the boiler as described below:

• This warranty is only valid if the boiler is installed

and operated in accordance with our Installation
and Operation Manual.

• This warranty shall cover leaks in pressure vessel

(as described above) when upon inspection by
seller, such damage is attributed to unequal
expansion, often described as “thermal shock.”

• This warranty does not cover damages or failures

that can be attributed to corrosion, scale, dirt or
sludge accumulation in the boiler, low water
conditions, failure of any safety devices or any
other improper service, operation or neglect.

FLUE GAS CORROSION WARRANTY

Subject to the terms and conditions herein, Seller
warrants to the original owner at the original
installation site that the pressure vessel and flue
collector are covered against failure due to fireside flue
gas corrosion per the schedule as follows:

A. Upper and Lower Pressure Vessel Headers -

10 years from date of shipment.

B. Flexible Boiler Tubes -

5 years from date of shipment.

C. Flue Collector Sides, Top and Bottom -

5 years from date of shipment.

BURNER HEAD WARRANTY

Subject to the terms and conditions herein, Seller
warrants to the original owner at the original
installation site that the burner head will be free from
defects in materials and workmanship for a period of
one year after the date of shipment.

LIMITED WARRANTY

Subject to the terms and conditions herein, Seller
warrants to the original owner at the original
installation site those products manufactured by Seller
(“Products”) comply, at the time of manufacture, with
recognized hydronics industry regulatory agency
standards and requirements then in effect and will be
free from defects in materials and workmanship for a
period of one year after the date of shipment.

REMEDY

A. The sole remedy for breach of this warranty is

expressly limited to the repair or replacement of
any part found to be defective under conditions of
normal use within the Warranty Period. Labor for
removal and /or installation is not included.

B. Warranty – The owner must notify the original

installer of the Product and Seller (Attention:
Bryan Steam, P.O. Box 3244, Lancaster, PA
17604-3244), in writing, within the Warranty
Period, providing a detailed description of all

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

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claimed defects. Transportation to a factory or
other designated facility for repairs of any products
or items alleged defective shall, in all events, be the
responsibility and at the cost of the owner.

Exclusions

Seller shall have no liability for and this warranty does
not cover:

A. Incidental, special or consequential damages, such

as loss of the use of products, facilities or production,
inconvenience, loss of time or labor expense involved
in repairing or replacing the alleged defective Product.

B. The performance of any Product under

conditions varying materially from those under which
such Product is usually tested under industry standards
as of the time of shipment

C. Any damage to the Product due to abrasion,

erosion, corrosion, deterioration, abnormal
temperatures or the influence of foreign matter or
energy.

1. Defective installations in general and

specifically, any installation, which is made:

a. In violation of applicable state or

local plumbing housing or building
codes,

b. Without a certified ASME, pressure

relief valve, or

c. Contrary to the written instructions

furnished with the unit.

2. Adverse local conditions in general and,

specifically, sediment or lime precipitation in
the tubes and/or headers or corrosive
elements in the atmosphere.

3. Misuse in general and, specifically, operation

and maintenance contrary to the written
instructions furnished with the unit,
disconnection, alteration or addition of
components or apparatus, not approved by
Seller, operation with fuels or settings other
than those set forth on the rating plate or
accidental or exterior damage.

D. The design or operation of owner’s plant or

equipment or of any facility or system of which any
Product may be made a part.

E. The suitability of any Product for any particular

application.

F. Any failure resulting from misuse, modification

not authorized by Seller in writing, improper
installation or lack of or improper maintenance.

G. Equipment furnished by the owner, either

mounted or un-mounted, or when contracted for by
the owner to be installed or handled.

H. Leakage or other malfunction caused by:

I. Production of noise, orders, discoloration or rusty

water.

J. Damage to surrounding area or property caused by

leakage or malfunction.

K. Costs associated with the replacement and/or

repair of the unit including: any freight, shipping or
delivery charges, and removal, installation or
reinstallation charges, any material and/or permits
required for installation, reinstallation or repair, charges
to return the boiler and or components.

Seller’s liability under this warranty shall not in any case
exceed the amount paid for the Product found to be
defective.

Third-Party Warranties

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]

For goods or components not manufactured by Seller,
the warranty obligations of Seller shall, in all respects,

Form: 2435

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Revision: 9
Free Flex Installation and Operation Manual Date: 9-1-2017

conform and be limited to one year from the date of
shipment.

Severability

To the extent that any provisions shall of this warranty
would be void or prohibited under applicable law, such
provisions shall be limited in effect to the minimum
extent necessary to render the remaining provisions
hereof enforceable.

Bryan Steam LLC, 783 N Chili Ave, Peru IN 46970 Web: www.bryanboilers.com

Phone: [phone] Fax: [phone] Email: [e-mail]