Bryan Boilers AB Series Installation, Operation & Service Manual Download

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Stack

Diam.

(in.)

Table 1.8.15C: Approximate Stack Capacities (MBH)

(Based on Atmospheric Boiler with Draft Hood)

100

125

150

200

100

120

140

150

170

200

220

250

270

280

300

320

350

380

400

430

450

510

550

640

130

160

190

210

240

270

310

340

360

390

410

430

480

510

550

580

620

690

760

870

180

210

250

280

310

360

400

440

480

510

540

570

620

670

720

760

810

900

990

1140

220

270

320

350

390

450

510

560

600

640

680

720

790

850

910

970

1020

1140

1250

1450

280

330

400

430

490

560

630

690

750

800

850

890

980

1060

1130

1200

1260

1410

1550

1790

400

480

570

630

700

810

910

1000

1080

1150

1220

1290

1410

1520

1630

1730

1820

2040

2330

2580

550

650

780

860

960

1110

1240

1360

1470

1570

1660

1750

1920

2070

2220

2350

2480

2770

3040

3510

720

850

1020

1120

1250

1450

1620

1770

1920

2050

2170

2290

2510

2710

2900

3070

3240

3620

3970

4590

910

1080

1290

1420

1590

1830

2050

2250

2430

2590

2750

2900

3180

3430

3670

3890

4100

4590

5030

5810

1130

1340

1600

1750

1960

2260

2530

2770

3000

3200

3400

3580

3920

4240

4530

4810

5070

5670

6210

7170

1370

1620

1940

2120

2370

2740

3060

3360

3630

3880

4110

4340

4750

5130

5480

5820

6130

6860

7510

8680

1630

1930

2300

2530

2820

3260

3650

4000

4320

4610

4900

5160

5650

6110

6530

6920

7300

8160

8940

10330

1910

2260

2710

2960

3320

3830

4280

4690

5070

5420

5750

6060

6640

7170

7660

8130

8570

9580

10490

12120

2220

2630

3140

3440

3850

4440

4970

5440

5880

6280

6660

7030

7700

8310

8890

9430

9940

11110

12170

14060

2550

3010

3600

3950

4420

5100

5700

6250

6750

7210

7650

8070

8840

9540

10200

10820

11410

12760

13970

16140

2900

3430

4100

4490

5020

5800

6490

7110

7680

8210

8710

9180

10050

10860

11610

12310

12980

14510

15900

18360

3270

3870

4630

5070

5670

6550

7320

8020

8670

9270

9830

10360

11350

12260

13110

13900

14650

16390

17950

20730

3670

4340

5190

5670

6360

7350

8210

9000

9720

10390

11020

11620

12730

13750

14700

15590

16430

18370

20120

23240

6530

7730

9230

10120

11310

13060

14600

16000

17280

18470

19600

20660

22630

24400

26130

27710

29210

32660

35780

41320

8260

9780

11690

12810

14320

16530

18480

20250

21870

23380

24800

26140

28640

30930

33070

35080

36970

41340

45290

52290

10200

12070

14430

15810

17680

20410

22820

25000

27000

28870

30620

32280

35360

38190

40830

43310

45650

51040

55910

64560

14700

17390

20780

22770

25460

29400

32870

36000

38890

41570

44100

46480

50920

55000

58800

62360

65740

73500

80510

92970

NOTE: The above vent input capacities in MBH (thousands of Btu/hr) are sea level ratings for double wall or insulated vents allowing for a system K factor of

7.5. Apply the correction factors for altitude, other K-factors and boiler draft control correction factors.

Summary of Contents for AB Series

Page 1: ...ion Operation Service Manual for Atmospheric Water Boilers E Mail bryanboilers iquest net Internet www bryanboilers com BRYAN BOILERS 783 N CHILI AVENUE PERU INDIANA 46970 Telephone 765 473 6651 Fax 765 473 3074 ...

Page 2: ...ld up an insulating floor under the boiler using high temperature mineral fiber board at least 1 1 2 thick 1 2 CLEARANCES See Table 1 for minimum clearances to wall ceilings or obstructions The clearances in Table 1 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 ...

Page 3: ...ER 50 WATER STEAM TO 50 STEAM OVER 50 A 18 36 18 48 24 24 18 36 24 24 B 24 24 48 96 48 36 48 24 48 48 CV CH 18 36 18 36 24 24 24 24 24 24 D 48 96 18 36 24 24 24 24 24 24 EL ER 24 24 18 36 24 24 24 24 32 32 1 F Series boilers are approved for installation on combustible flooring Do not install on carpeting A Clearance above boiler B Front of boiler CV Clearance from gas vent measured vertically abo...

Page 4: ...ing pool water the heating system connections discussed above are capped The relief valve connections are still required Water connections are made only to the indirect heat exchanger s according to the piping drawing included in this manual An automatic boiler fill valve is provided with the boiler This valve must be connected to the fresh water system With some units this connection is made to t...

Page 5: ... ANSI NFPA 70 1981 1 7 COMBUSTION AIR SUPPLY IMPORTANT Positive means for supplying an ample amount of outside air allowing 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 i...

Page 6: ...nel in the boiler room In colder climates provision should also be made to heat the boiler room if necessary for personnel comfort CAUTION Protection from combustion air contamination Where corrosive or flammable process fumes are present in the vicinity of the boiler room or the air stream for the combustion air supply it is essential that suitable means be provided for their safe disposal The bo...

Page 7: ...tal input of appliances connected to the chimney or vent by 1 000 000 Then multiply this result times the value listed in the table for PPH emissions MANUAL REFERENCES See Figure 1 8 1 for a graphics listing of applicable sections of this manual for each section of the vent system FIGURE 1 8 1 VENT DESIGN INSTRUCTIONS REFERENCE TABLE 1 8 1A ESTIMATING FLUE GAS VOLUMETRIC FLOW RATE Approximate Flue...

Page 8: ...mospheric Gas Barometric D R N A N A N A N A 0 115 0 115 70 90 0 120 0 120 75 100 N A N A N A N A 1 8 2 CLEARANCES The vent system and draft control devices must be installed so as to achieve the clearances to surfaces outlined in Table 1 2 1 Minimum Clearances chart in this manual See also Table 1 8 9 for vent clearances All clearances must comply with the National Fuel Gas Code NFPA54 and with a...

Page 9: ... THE BOILER MUST BE PROVIDED WITH A SINGLE ACTING BAROMETRIC DRAFT CONTROL NOT WITH A DRAFT DIVERTER THE FAN MUST BE INTERLOCKED WITH THE BOILER 1 8 5 DRAFT CONTROL INSTALLATION DRAFT DIVERTER Each atmospheric gas boiler is supplied with a VERTICAL DRAFT DIVERTER or a BAROMETRIC DRAFT REGULATOR THESE DEVICES MUST BE INSTALLED WITHOUT MODIFICATION DO NOT SHORTEN THE COLLAR LENGTH OF A DRAFT DIVERTE...

Page 10: ...ding or removing weights washer type Item F at the end of the chains DO NOT MOVE THE LARGE WEIGHTS ATTACHED DIRECTLY TO THE GATE Item G as they are used only for adjustment at the factory DRAFT should generally be set between 0 02 and 0 04 w c The actual setting must be determined by taking a CO2 reading and a CO reading at the boiler flue Reference Table 2 5A for appropriate values COMBUSTION REA...

Page 11: ...wall metal pipe should be insulated to prevent excessive heat in the boiler room and to avoid ignition and spillage problems as well as corrosion from excessive condensation MASONRY METAL AND FACTORY BUILT CHIMNEYS Installation of factory built vents and chimneys must comply with the vent listing with the vent manufacturer s instructions and with adherence to the codes and clearances as outlined h...

Page 12: ...nch per foot LENGTH OF VENT CONNECTOR The vent connector must be as short as possible and the boiler close as practical to the chimney or vent The horizontal run of an uninsulated vent connector to a natural draft chimney or vent servicing a single appliance must not be more than 75 of the height of the chimney or vent above the vent connector The horizontal run of an insulated vent connector to a...

Page 13: ...t and the thimble in which case the thimble may be 2 larger For unlisted appliances or for barometric provided with barometric dampers the thimble must be 6 inches larger in diameter than the vent SINGLE WALL METAL VENT PIPE USED TO VENT STEAM BOILERS OPERATING OVER 50 PSIG MUST NOT PASS THOUGH WALLS OR PARTITIONS CONSTRUCTED OF COMBUSTIBLE MATERIAL 1 8 9 CHIMNEY VENT CONSTRUCTION VERTICAL SECTION...

Page 14: ...amined to ascertain that it is clear and free of obstructions Cleanouts must be constructed such that they will remain tightly closed when not in use Tee fittings used as cleanouts or condensate drains must have tight fitting caps to prevent entrance of air into the chimney at such points When an existing masonry chimney is unlined and local experience indicates that vent gas condensate may be a p...

Page 15: ... building within a distance of 25 feet from the vent Reference NFPA 211 MINIMUM HEIGHT ABOVE DRAFT CONTROL Chimneys and gas vents must extend at least 5 feet above the highest connected draft diverter outlet barometric draft control or any appliance flue outlet CLEARANCE FROM AIR INLETS The vent or chimney must terminate no less than 3 feet above any forced air inlet within a distance of 10 feet I...

Page 16: ... one vent diameter above the vent exit 1 8 13 AUTOMATIC VENT DAMPERS ONE APPLIANCE ONLY An automatic vent must be installed such that it serves only one appliance vent that to which is properly interlocked LISTING REQUIREMENTS Automatic vent dampers if used must be of a listed type INSTALLATION The damper installation must comply with Appendix I J or K of the National Fuel Gas Code NFPA 54 The ins...

Page 17: ... than for a natural draft system Sizing of induced draft fans should be done using the recommendations of the fan manufacturer and the ASHRAE Handbook FIG 1 8 14 SUGGESTED APPLIANCE VENTING PROCEDURE MULTIPLE APPLIANCE INSTALLATIONS Bryan recommends that boilers and other gas appliances be individually vented when possible See figure 1 8 14A Individual venting provides better draft control and fue...

Page 18: ...has been provided to give the circular equivalent of a rectangular duct These equivalent values account for the higher pressure drop per cross sectional area for rectangular ducts STEP 1 EQUIVALENT INPUT DRAFT CONTROL FACTOR Determine the boiler system Draft Control Factor F1 from Table 1 8 15A Determine the boiler or total system input in MBH This is done by dividing the boiler or total system in...

Page 19: ...eed to Step 4 to calculate the system k factor to determine the actual stack diameter required STEP 4 CALCULATE SYSTEM K FACTOR The system k factor accounts for the pressure drop through fittings and vent piping It is calculated by adding up the individual k factors for each of the fittings plus the k factor for the vent pipe s From Table 1 8 15D find the k factors for each of the elbows tee fitti...

Page 20: ...sing this adjusted equivalent input check the stack diameter by following Steps 2 thru 3 again If the stack diameter remains the same the sizing is complete If not redo Steps 4 thru 5 etc until an acceptable result is achieved Table 1 8 15E K Factor Equivalent Input Correction Factor F3 K Factor F3 K Factor F3 K Factor F3 K Factor F3 K Factor F3 1 00 0 37 1 50 0 45 2 00 0 52 2 50 0 58 3 00 0 63 3 ...

Page 21: ... 5160 5650 6110 6530 6920 7300 8160 8940 10330 26 1910 2260 2710 2960 3320 3830 4280 4690 5070 5420 5750 6060 6640 7170 7660 8130 8570 9580 10490 12120 28 2220 2630 3140 3440 3850 4440 4970 5440 5880 6280 6660 7030 7700 8310 8890 9430 9940 11110 12170 14060 30 2550 3010 3600 3950 4420 5100 5700 6250 6750 7210 7650 8070 8840 9540 10200 10820 11410 12760 13970 16140 32 2900 3430 4100 4490 5020 5800 ...

Page 22: ......

Page 23: ... 54 17 21 23 26 29 31 33 35 39 39 40 42 44 48 52 56 59 62 60 18 21 24 27 30 32 34 37 39 40 42 44 46 50 55 59 62 66 1 8 16 SPECIAL APPLICATIONS FLUE GAS ECONOMIZERS When applying flue gas economizers care must be taken to assure that 1 Proper draft must be maintained This requires that the gas side pressure drop be considered and that the economizer exchanger must be designed so as to allow cleanin...

Page 24: ... s literature on the components included in the manual MAIN GAS COCK MANUAL SHUTOFF VALVE The main shutoff cock is located in the gas line ahead of the main gas pressure regulator This manual valve must be CLOSED during servicing of the burners DO NOT OPEN THIS VALVE IF THE AUTOMATIC GAS VALVES ARE OPEN Refer to Section 2 of this manual and to Lighting Instructions for proper use of this valve A s...

Page 25: ... power to the automatic gas valve s Carefully read the enclosed instruction sheet on the pilotstat ELECTRONIC FLAME SUPERVISORY CONTROLS Electronic controls sense the flame using either a flame rod wire which conducts electrical current though the flame or and ultraviolet scanner a device which senses the ultraviolet light emitted by the flame to sense the presence of a pilot flame This type of co...

Page 26: ...re 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 It is often necessary to retighten such fittings after installation and after the boiler has been operated for some time Replace tube access panels before proceeding to start boiler 1 10 2 TES...

Page 27: ... sheet in the boiler manual for the proper adjustment of the pilot burner This is absolutely essential before attempting to adjust the main burner 2 1 3 ADJUST BOILER INPUT S The boiler input must be adjusted for both maximum and minimum input values which are listed on the boiler nameplate on the boiler First adjust the maximum input rating using the method described in the Lighting Instructions ...

Page 28: ...both valves achieving full input 2 2 FIRING RATE ADJUSTMENT GAS METER READINGS 2 2 1 CHECKING BURNER INPUT The burner input rate can be checked by taking readings from the gas meter Please note checking the rate with a meter is the only way to be sure of input Manifold readings are only an approximate value and may vary from unit to unit In order to obtain accurate data there must be no other appl...

Page 29: ...ude an outdoor reset control This control increases the boiler operating temperature with a decrease in outdoor air temperature and decreases the boiler operating temperature with a rise in the outdoor temperature For gas fired boilers it is essential that the minimum operating temperature of the boiler never drop below 130 F even at 70 F outdoor temperature Reference Section 3 4 Also refer to the...

Page 30: ...up water is introduced as needed Carefully read the enclosed literature on the Low Water Cut off controls particularly installing operating and servicing 2 4 9 OTHER CONTROLS Additional controls as required for the particular installation may also be provided Refer to the literature on these devices included in the Boiler Manual All such devices must be operationally tested to assure reliable oper...

Page 31: ...und the edge of the draft hood relief opening or barometric If the venting system is operating correctly the match flame will be drawn toward the draft hood relief opening Otherwise the products of combustion will tend to push the flame and extinguish it CAUTION IF THE PRODUCTS OF COMBUSTION ARE BEING EMITTED INTO THE ROOM VENTING SYSTEM NOT OPERATING CORRECTLY THE BOILER MUST NOT BE OPERATED UNTI...

Page 32: ...ared to operate and maintain the boiler properly The operating instructions should be kept in the pocket in the boiler for F Series boilers or adjacent to the boiler for all others READ THE MANUAL BEFORE ATTEMPTING A START UP 2 7 MAINTENANCE SCHEDULE 2 7 1 POSTING SCHEDULE Post a maintenance schedule in accordance with the recommendations in this manual A copy of a typical schedule is included in ...

Page 33: ...stem 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 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 Fill the system with this solution venting all air Then wi...

Page 34: ...nection to the tank Install a strainer in boiler return piping 3 3 BOILER WATER TREATMENT 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 wate...

Page 35: ...ssibly hazardous boiler operation Failure to do so may result in fire explosion potential or asphyxiation A combustion test and burner adjustments should be undertaken at once Rust on the tubes indicates that boiler operating temperatures are too low The set point of the boiler operating control must be no less than 130 F for natural gas or propane firing and 170 F for oil fired boilers Boilers eq...

Page 36: ...akage tests on pilot and main gas or main oil fuel valves as specified in manufacturer s instructions 2 Check operating control high limit low fire start control and low water cutoff as specified in manufacturer s instructions 4 For units equipped with power burners check air atomizing interlock fuel valve interlock switch purge switch burner position interlock and fuel changeover control as speci...

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