Bryan Boilers AB Series, Installation, Operation & Service Manual

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 ...

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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...