Bryan Boilers FREE FLEX Manuel utilisateur

Free Flex I&O manual Revision: 13

P/N 105641-03 Date: 06/24/2022

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]

FREE FLEX



CONDENSING BOILER

INSTALLATION & OPERATION MANUAL

For service and repair to the boiler, call your heang contractor. When seeking informaon on the boiler from

the manufacturer, provide boiler model and serial number as shown on the rang label.

Boiler Model: Serial Number:

Installaon Date: Type System:

Heang Contractor: Phone/Email:

Address:

WARNING

This manual must only be used by a qualied heating installer/service

technician. Read all instructions in this manual before installing. Perform

steps in the order given. Failure to comply could result in severe

personal injury, death, or substantial property damage.

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]



 

A. Important Informaon 6

B. Disclaimers and Local Codes 6

C. Test and Inspecons 7

D. Component Descripon 7

E. Touchscreen display. 7

 

A. Installaon Conformance 9

B. Boiler Foundaon 9

C. Clearance and Serviceability 9

 

A. Receiving the Boiler 11

B. Boiler Water and Condensate Connecons 11

C. Condensate Trap/Drain Assembly 12

D. Gas Supply Connecons 13

E. Combuson Air Supply System 13

 

A. General Venng Guidelines 16

B. Venng Design Requirements 17

C. Field Installaon 17

D. General Terminaon 24

E. Vent and Combuson Air Terminaons 28

F. Mulple Appliance Terminaons 30

G. Terminal Installaon 31

H. Polypropylene Venng 33

I. Oponal Room Air for Combuson 33

J. Removing Exisng Appliance 37

K. Special Installaon Requirements for

Massachuses 37

 

A. Electrical 39

B. Gas Supply Requirements 40

C. Sound Pressure Levels 40

D. Pump and Piping Requirements 40

 

A. Pre-Boil Out Flushing of System 42

B. Boiler Out Procedure 42

C. Replacement Boiler Installaons 43

D. Draining and relling the boiler & system 43

E. Boiler Water Treatment 44

 

A. Concert Boiler Control Display Navigaon 45

B. System Check 46

C. Power the Boiler 46

D. Power the Circulators 46

E. Pressurize the Fuel System 46

F. Boiler Commissioning 46

G. Commissioning Free Flex 1000 - Free Flex 3000

H. Dual Fuel Free Flex 1500 - Free Flex 6000 -

Switching Fuels 49

I. Commissioning Free Flex 1500 - Free Flex 6000

High Turndown or Dual Fuel 49

J. Finish Commissioning the Free Flex 1000 - Free

Flex 6000 50

K. Re-Starng Aer Prolonged Shutdown 50

L. Tesng Controls and Safety Devices 51

M. Ignion Failure 51

 

A. General Maintenance 52

B. Daily 52

C. Weekly 53

D. Monthly 53

E. Annually 53

F. Ignion Assembly Cleaning 53

G. Burner Assembly Cleaning 54

H. Heat Exchanger Cleaning 54

I. Tube Replacement Procedure 54

J. Safety and Operang Controls 58

K. Troubleshoong 59

 



   

 

 

 

 

 

seller)

 

 

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]



 

Figure 1: Free Flex 1000 External Boiler Connecons 8

Figure 2: Free Flex 1500-3000 External Boiler Connecons 8

Figure 3: Free Flex 3500-6000 External Boiler Connecons 8

 

Figure 4: Clearances and Serviceability 10

 

Figure 5: Condensate Drain Trap 12

Figure 6: Condensate Assembly Orientaon 12

 

Figure 7: Vent Terminal Clearances 25

Figure 8: Horizontal Sidewall Terminaon 29

Figure 9: Slopped Roof Terminaon 29

Figure 10: Flat Roof Vent Terminaons 30

Figure 11: Mulple Appliance Direct Vent Terminaon 32

Figure 12: Flexible Vent in Masonry Chimney with Separate Combuson Air Intake 36

 

 

 

Figure 13: Dungs Valve 48

Figure 14: Siemens Valves 48

 

Figure 15: Free Flex 1000-3000 Ignion Assembly 53

Figure 16: Free Flex 3500-6000 Ignion Assembly 54

Figure 17: Panel Removal in Preparaon for Tube Inspecon - Free Flex 1000 55

Figure 18: Panel Removal in Preparaon for Tube Inspecon - Free Flex 1500 - Free Flex 3000 55

Figure 19: Panel Removal in Preparaon for Tube Inspecon - Free Flex 3000 - Free Flex 6000 56

Figure 20: Tube Puller Inseron 57

 



   

 

Figure 21: Typical Horizontal Vent Piping 64

Figure 22: Typical Vercal Pressurized Venng 64

 

Figure 23: Typical Horizontal Air Intake Piping 65

Figure 24: Typical Vercal Air Intake Piping 65

 

Figure 25: Single Boiler, Primary / Secondary 66

Figure 26: Mulple Boilers, Primary Reverse-Return Piping 67

Figure 27: Mulple Boilers, Primary / Secondary Reverse Return Piping 68

Figure 28: Mulple Boilers, Primary / Secondary Piping 69

Figure 29: Mulple Boilers, Primary / Secondary With Indirect Water Heater 70

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]

 

 

Figure 30: Free Flex 1000 Wiring Diagram 72

Figure 31: Free Flex 1500 To Free Flex 3000 115 VAC Single Phase Wiring Diagram 74

Figure 32: Free Flex 1500 To Free Flex 3000 208 – 230 VAC Single Phase Wiring Diagram 76

Figure 33: Free Flex 2000 To Free Flex 3000 208-460 VAC Three Phase Wiring Diagram 78

Figure 34: Free Flex 1500 To Free Flex 3000 High Turndown 120 - 460 VAC Single or

Three Phase Wiring Diagram 80

Figure 35: Free Flex 1500 To Free Flex 3000 Dual Fuel 120-460 VAC

Single or Three Phase Wiring Diagram 84

Figure 36: Free Flex 3500 To Free Flex 6000 208-460 VAC Three Phase Wiring Diagram 88

Figure 37: Free Flex 3500 To Free Flex 6000 Dual Fuel 208-460 VAC Three Phase Wiring Diagram 92

seller)

 

 

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]



 

Table 1: Water Flow Switch Sengs 7

 

Table 2: Clearances and Serviceability 10

 

Table 3: Typical Condensate Flow Rate 12

 

Table 4: Vent and Combuson Air Pipe Diameters

and Maximum Lengths 18

Table 5: Vent and Combuson Air Equivalent Length

Calculaon Worksheet 18

Table 6: Vent Air Pressure Drop Data 19

Table 7: Combuson Air Pressure Drop Data 20

Table 8: Combuson Air and Flue Gas Requirements

Table 9: Approved Vent Manufacturers and

Materials 21

Table 10: Stainless Steel and CPVC Vent Adapters 21

Table 11: Polypropylene Vent Adapters 22

Table 12: Stainless Steel Vent and Intake

Terminaons 22

Table 13: Polypropylene Vent and Intake

Terminaons 22

Table 14: Recommended Venng Conguraons

and Material Opons 23

Table 15: Other than Direct Vent Terminal

Clearances 26

Table 16: Table of Acceptable Terminaons 27

 

Table 17: Electrical Requirements 39

Table 18: Gas Supply Requirements 40

Table 19: Sound Pressure Levels 40

Table 20: Minimum Water Flow Rates for Variable

Primary Pumping 41

Table 21: Maximum Water Flow Rate for Variable

Primary Pumping 41

Table 22: Water Flow Rates for Primary/Secondary

Pumping at 20°F ΔT 41

Table 23: Water Flow Rates for Primary/Secondary

Pumping at 40°F ΔT 41

Table 24: Water Flow Rates for Constant Volume

Primary Pumping 42

Table 25: GPM Increase for Glycol System 42

 

Table 26: Chemical Agents and Eects 44

Table 27: Recommended Feed Water Limits 45

 

Table 28: Siemens Nominal Low Fire O2 48

Table 29: Safety Device Tests 51

 

Table 30: Safety and Operang Controls 59

Table 31: General Troubleshoong 60

 

Table 32: Maximum Gas Capacity Of Schedule 40

Pipe 61

Table 33: Equivalent Lengths Of Standard Pipe

Fings And Valves 62

Table 34: Specic Gravity Correcon Factors 62



   

 

 

 

 

 

seller)

 

 

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]



A. Important Informaon

The following terms are used throughout this

manual to bring aenon to the presence of hazards

of various risk levels, or to important informaon

concerning product life. It is crical that all personnel

read and follow all the informaon provided in the

boxes marked DANGER, WARNING, CAUTION, and

NOTICE.

DANGER

Indicates an imminently hazardous situaon, which,

if not avoided, will result in death, serious injury or

substanal property damage.

WARNING

Indicates a potenally hazardous situaon, which,

if not avoided, could result in death, serious injury

or substanal property damage.

CAUTION

Indicates a potenally hazardous situaon, which, if

not avoided, may result in moderate or minor injury

or property damage.

NOTICE

Indicates specific instructions on installation,

operaon, or maintenance, which are important but

not related to personal injury hazards.

B. Disclaimers and Local Codes

Installaon must conform to the requirements of

the authority having jurisdicon. In the absence of

such requirements, installaon must conform to the

Naonal Fuel Gas Code, NFPA 54/ANSI Z223.1, and/

or CAN/CGA B149 Installaon Codes. Where required

by the authority having jurisdicon, the installaon

must conform to the Standard for Controls and Safety

Devices for Automacally Fired Boilers, ANSI/ ASME

CSD-1.

Installation, start-up, and maintenance of this

equipment can be hazardous and requires trained,

qualied installers and service personnel. Do not

install, operate, service or repair any components

of this equipment unless you are qualied and fully

understand all requirements and procedures. Trained

personnel refer to those who have completed Thermal

Solutions Service School training specific to this

product.

The boiler heat exchanger is manufactured and

stamped in accordance with ASME Boiler and Pressure

Vessel Code, Secon IV for a maximum allowable

working pressure and operang temperature of 160

psig (1103 kPa) and 210 F(99 C) respecvely. Aqua-stat

is factory set at 200 F (93 C).

NOTICE

Post these instructions and maintain in legible

condion.

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]

C. Test and Inspecons

Upon the compleon of boiler installaon, nal air-

fuel adjustments are to be made by factory trained

service personnel. The emissions data and the O2

levels at minimum and maximum input rate can be

found on the back side of the front-boiler’s door,

which can be referenced in the future by the boiler

operator(s) when troubleshoong and servicing the

boiler. In addion, the following tests and inspecons

are made on each boiler at the factory to ensure it

meets our highest safety and funconality standards.

• ASME hydrostac test inspecon

• Electrical components inspecon

• Operang & eciency test

• Final engineering inspecon

• Crang inspecon

DANGER

DO NOT store or use gasoline or other ammable

vapors or liquids in the vicinity of this or any other

appliance.

If you smell gas vapors, DO NOT try to operate any

appliance—DO NOT touch any electrical switch or

use any phone in the building. Immediately, call the

gas supplier from a remotely located phone. Follow

the gas supplier’s instrucons or if the supplier is

unavailable, contact the re department.

D. Component Descripon

(See Figure 1, Figure 2 and Figure 3)

E. Touchscreen display.

The display provides easy access for viewing

and adjusting boiler operational parameters,

monitoring historical performance characteriscs and

annunciang boiler alarm/lockout condions.

1. Boiler On/O switch.

2. Manual gas shutoff valve. The boiler is

equipped with two manual gas shut o valves,

one located on the incoming gas supply line

outside of the boiler, and the other downstream

of the main gas valve.

3. Main gas supply connecon.

4. Pressure relief valve. The pressure relief

protects the heat exchanger from an over-

pressure condion.

5. Ducted combuson air ange.

6. Flue gas vent outlet. The boiler comes with

a standard AL 29-4C® stainless steel vent

connecon.

7. Boiler water ow switch. The boiler water

ow switch is adjustable within the parameters

listed in Table 1. (Located inside the boiler on

Free Flex 1500 - Free Flex 6000)



Sengs Mode Of Operaon

Switch Closed Switch Open

Minimum 18 13

Maximum 50 45

8. Return water connection. A 3” diameter

Victaulic grooved connecon is provided on

the Free Flex 1000. A 3”, 150# class, ange is

provided on the Free Flex 1500 – 3000. A 6”,

150# class, ange is provided on the Free Flex

3500-6000.

9. Clean out and inspecon. The Free Flex 1000

has a 3” diameter Victaulic grooved connecon

is provided for inspecng and cleaning sediment

from the heat exchanger. The Free Flex 1500-

6000 has a 1” NPT pipe for blow down to clean

sediment from the heat exchanger and a 3”

removable plug for inspecng.

10. Supply water connection. A 3” diameter

Victaulic grooved connecon is provided on

the Free Flex 1000. A 3”, 150# class, ange

is provide on the Free Flex 1500 – 3000. A 6”,

150# class, ange is provided on the Free Flex

3500-6000.

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]

11. Air vent. The boiler is provided with an internal

dip tube that traps liberated air from the boiler

water. The air vent allows the trapped air to

escape from the boiler.

References 13 to 15 are not used on the Free Flex 1000

12. Boiler reset push buon

13. Boiler water temperature gauge.

14. Boiler water pressure gauge.

References 16 to 18 are only used on Free Flex 3500 – Free

Flex 6000

15. Boiler Hand/O/Auto

16. Push Button Display. The display provides

easy access for viewing and adjusng boiler

operaonal parameters and provides alarm/

lockout codes.

17. Temperature Display. Provides for temperature

set points and actual temperature.













3 4

117

3 4

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]



The customer should examine the equipment for

any damage. It is the responsibility of the installer

to ensure all parts supplied with the equipment are

ed in a correct and safe manner.

WARNING

This boiler requires regular maintenance and service

to operate safely. Follow the instrucons contained

in this manual.

WARNING

Improper installation, adjustment, alteration,

service, or maintenance can cause property damage,

personal injury or loss of life. Read and understand

the enre manual before aempng installaon,

start-up operaon, or service. Only an experienced,

skilled installer or service agency must perform

installaon and service.

WARNING

This boiler must be properly vented.

This boiler needs fresh air for safe operation

and must be installed so there are provisions for

adequate combuson and venlaon air.

A. Installaon Conformance

Installaon must conform to the requirements of

the authority having jurisdicon. In the absence of

such requirements, installaon must conform to the

Naonal Fuel Gas Code, NFPA 54/ANSI Z223.1, and/

or CAN/CGA B149 Installaon Codes. Where required

by the authority having jurisdicon, the installaon

must conform to the Standard for Controls and Safety

Devices for Automacally Fired Boilers, ANSI/ ASME

CSD-1.

B. Boiler Foundaon

Before uncrating, the boiler location should be

prepared. The boiler should set upon a good level

concrete oor. If the boiler is not level or the oor is

not in good condion, a concrete foundaon should

be built, the dimensions being larger than the outside

dimensions of the boiler base. A 4” high housekeeping

pad is suggested.

WARNING

Do not install boiler on combusble ooring.

C. Clearance and Serviceability

See Figure 4 and Table 2 for minimum clearances to

walls, ceilings, or obstrucons. These clearances are

intended as a general recommendaon only. Local

codes must be applied to specic installaons and

the minimum clearances established accordingly.

Provisions must also be made for service, accessibility

and clearance for piping and electrical connecons.

Do not obstruct combustion air and ventilation

openings with piping or any other construction.

All boilers must be installed in a space that is large

compared to the boiler.

Bryan Steam, LLC www.bryanboilers.com

Phone: 765-473-6651 783 N Chili Ave, Peru, IN 46970 [email protected]



Dim Descripon

Free

Flex

1000

Free Flex

1500-3000

Free Flex

3500-6000

AClearance Above Top of Boiler 6” 6” 6”

BFront of Boiler – Burner End 24” 32” 43”

CH From Chimney or Vent Collector measured

horizontally 18” 18” 18”

CV From Chimney or Vent Collector measured

vercally 18” 18” 18”

D Rear of Boiler - opposite burner end 6” 6” 6”

EL Le Side - tube access side on standard con-

strucon 16” 23” 23”

Right Side – tube access side on standard

construcon

(Free Flex 3500-6000)

6” 6” 23”

EC Free Flex 1500 - 3000 only N/A 23” N/A



Boiler

Flue Gas

Vent

Boiler

EL ER

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