Bryan Boilers Forced Draft Steam Boilers manual

Installation Operation Service Manual for Forced Draft Steam 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[...]

INSTALLATION INSTRUCTIONS FORCED DRAFT STEAM BOILERS NOTE : • Please read all of instructio n manual before attempting insta llation. • Insurance and local or state regulatory codes may co ntain additional or more stringent requirements than those contained in this manual. Installati on must conform to these codes and any other authority having[...]

MINIMUM CLEARANCES NOTE: These boilers are intended to be installed in a r oom which is large compared to the size o f the boiler. They are not intended for alcove installation and are suitable for installation on non- combustible flooring only. DIMENSIO N D-SERIES F-SERIES 1 CL-SERIES K-SERIES RV, RW & AB SERIES WATER / STEAM TO 50# STEAM OVER[...]

1.4 BOILER CONNECTIONS 1.4.1 GENERAL Do not run any pipes along the access panel side of the boiler. Maintain clearances as shown on the dimensional drawing for servicing of the boiler tubes. Provide a t least 36" from the gas train and burner, unless a larger dimension is indicated on the dimensional. All piping should be designed and install[...]

1.5 GAS SUPPLY CONNECTIO N - FORCED DRAFT UNITS The installation must conform completely to the requirements of the authority having ju risdiction, 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 Installation Code for Gas Burning Appliances and Eq[...]

1.6 ELECTRICAL CONNE CTION IMPORTANT: All electrical connections must conform to the National Electrical Code and to all other applicable State and Local Codes. Forced draft boilers may require a high voltage connection. See boiler wiring diagram and equipment list for details. Equipment Grounding - The boiler must be grounded in accordance with th[...]

Ventilation Air: In addition to air needed for combustion, sufficient air must be sup plied for ventilation, including air required for comfort and proper working conditions for personnel 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 combus[...]

FIG. 1.8.1: VENT DESIGN INSTRUCTION - REFERENCES TABLE 1.8.1 A: ESTIMATING FLUE G AS VOLUMETRIC FLOW R ATE Approx imate Flue Gas VOLUMETR IC FLOW RA TE (Per 1000 Bt u/hr Inp ut) (Multiply f actor listed times boil er input in MB H) BOILER TYPE SCFM Per 1000 Btu/hr INPUT ACFM Per 1000 Btu/hr INPUT APPROXIMATE FLUE GAS TEMPER ATURE Water & 15# S [...]

TABLE 1.8.1 C: ESTIMATING FLUE G AS EMISSION S Estimated Emissions (Volumetric Flow Rate Per Million Btu/hr Input) (Multiply PP H listed times boile r input divi ded by 1,000, 000) BOILER TYPE PARTICULATES NOx CO SOx Hydrocarb ons PPH per MMBH PPM PPH per MMBH PPM PPH per MMBH PPM PPH per MMBH PPM PPH per MMBH PPM Gas Fired Oil Fired N/A 0.020 N/A [...]

1.8.7 ACCEPTABLE VENT TYPES LISTED GAS VENTS Listed gas vents must be applied only on those applications for which they are lis ted. Type B gas vents are NOT listed for use on for ced draft appliance vent systems. Installation of these vent s must comply with the vent listing, with the vent manufacturer's instructions and with complete adheren[...]

1.8.5 VENT CONNECTOR S (HORIZONTAL RUNS) CONSTRUCTION Vent connectors may be of any of the acceptable constructions listed in th is manual. AVOID UNNECESSARY BENDS The vent connector must be installed so as to avoid turns or other construction features which create excessive resistance to flow of flue gases. JOINTS Vent connectors must be firmly at[...]

1.8.6 CHIMNEY & VENT CO NST RUCTION (VERTI CAL SECTION) INSTALLATION OF FACTORY BUILT SYSTEMS Listed gas vents and factor y built chimneys must be installed in accordance with their listings and the manufacturer's instructions. Vents and venting systems passing through roofs must extend though the roof fla shing, roof thimble or roof jack.[...]

1.8.7 MARKING O F GAS VENTS In those localities where solid and liquid fuels are used extensively, gas vents must be plainly and permanently identified by a label read ing: "This gas vent is for appliances which burn gas only. Do not connect to incinerators or solid or liquid fuel burning appliances." This label must be attached to the wa[...]

PROTECTION AGAINST BLOCKAGE OR OBSTRUCTION The chimney or vent exit design must prevent any possibility of blockage by snow or any other obstruction. VENTILATING HOODS AND EXHAUST SYSTEMS Ventilating hoods or exhaust systems may be used to vent atmospheric gas appliances. When these are used, however, such mechanical exhaust devices must be electri[...]

AUTOMATIC VENT DAMPERS MUST BE INSTALLED ONLY BY QUALIF IED SERVICE TECHNICIANS. FAILURE TO PROPERLY INSTALL A VENT DAMPER WILL CREATE A SEVERE HAZARD. PERFORMANCE TEST The automatic vent damper must be tested after installation to assure its proper and safe operation. AUTOMATIC VENT DAMPERS MUST BE IN THE OPEN POSITION AT ANY TIME THE APPLIANCE MA[...]

be done with 45 elbows and not by "bullheading" directly into the vent con nector at 90 angles. "Bullhead" connections generally cause excessive turbulence and poor draft conditions. On vent connectors serving multiple appliances, the diameter of the piping should be increased at each appliance's entrance so as to pro[...]

Table 1.8.15B ALTITUDE CORRECTION FACTOR, F 2 (Multiple factor times sea le vel input, MBH) Altitude (ft) Factor, F 2 Altitude (ft) Factor, F 2 0 to 1999 2000 2500 3000 3500 4000 4500 5000 5500 1.00 1.075 1.096 1.116 1.136 1.157 1.180 1.202 1.25 6000 6500 7000 7500 8000 8500 9000 10000 1.247 1.272 1.296 1.322 1.346 1.373 1.399 1.453 STEP 3: SEL ECT[...]

STEP 5: CORRECT EQUIVALENT INPUT FOR SYSTEM K-FACTOR The capacities listed in Table 1.8.15C are based on a system k-factor equal to 7.5. For any other k-factor, the vent capacity must be adjusted. This is accomplished by adjusting the equivalent input for the system using a k-factor correction factor, designated F 3 . Refer to Table 1.8.15E for the[...]

Stack Diam. (in.) Table 1.8.15 C: Approxi mate Stack Ca pacities (MB H) (Based on A tmospheric Boiler with Draft Ho od) 5 7 10 12 15 20 25 30 35 40 45 50 60 70 80 90 100 125 150 200 6 100 120 140 150 170 200 220 250 270 280 300 320 350 380 400 430 450 510 550 640 7 130 160 190 210 240 270 310 340 360 390 410 430 480 510 550 580 620 690 760 870 8 18[...]

Table 1.8.15F: CIRCULAR EQUIVALENTS OF RECTANGULAR BREECHINGS & STACKS WIDTH (INCHES) HEIGHT (INC HES) 6 8 10 12 14 16 18 20 22 24 26 28 30 36 42 48 54 60 6 7 8 8 9 10 10 11 11 12 12 13 13 14 15 16 17 17 18 8 8 9 10 11 11 12 13 13 14 15 15 16 16 15 19 20 21 21 10 8 10 11 12 13 14 15 15 16 17 17 18 18 17 21 22 23 24 12 9 11 12 13 14 15 16 17 18 [...]

1.9 BURNERS AND GAS TRAI N - FORCED DRAFT BOILERS GENERAL Refer to separate manual on the forced draft burner for start-up and adjustment procedures. Do not attempt to start bu rner when excess oil has accumulated, or when the combustion chamber is full of gas, or if chamber is very hot. FUEL CONNECTIONS Gas supply connections must comply with the [...]

START-UP AND OPERATION STEAM BOILERS WARNING : IMPROPER SERVICING AND START-UP OF THIS EQUIPM ENT MAY CREATE A POTENTIAL HAZARD TO EQUI PMENT AND TO OPERATORS OR PERSONS IN THE BUILDI NG. SERVICING AND START-UP MUST BE DO NE ONLY BY FULLY TRAINED AND QUALIFIED PERSONNEL. CAUTION: BEFORE DISCONNECTING OR OPENING ANY FUEL LINE, OR BEFORE CLEANING OR [...]

NOTE THE LOW FIRE ADJUSTMENT SHOULD RESULT IN A GAS PRESSURE ON THE BURNER MANIFOLD EQUAL TO 1" WATER COLUMN FOR NATURAL GAS AND 3" FOR PROPANE GAS. 2.1.5 MINIMUM INPUT ADJUSTMENT - COMBINATION GAS VALVES (VR850 OR VR852) The minimum input on these gas valve s is NOT adjustable. The maximum input must be properly set as outlined in Lighti[...]

2.3 SAFETY SHUT- OFF DEVI CES (FLAME SUPERVISION) 2.3.1 FLAME SUPERVISORY SYSTEM The boiler is equipped with a flame supervisory system, either the Thermocouple type (such as a combination gas valve or a pilotstat) or electronic type (such as the RA890, or RM7895). The purpose of this device is to detect the main or pilot flame, depending on the ty[...]

Water Cut-off controls, particularly installing , operating and servicing. 2.4.6 OTHER CONTROLS Additional controls as re quired 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 operation of the boiler and s[...]

FORCED DRAFT OIL FIRED BOILERS BOILER SERIE S DRAFT AT BOILER OUTLET (i.w.c.) CO 2 @ HIGH FIRE O 2 @ HIGH FIRE CO (ppm) SMOKE NO. D -0.01 TO -0.04 10.0 TO 12.0 % 4.0 TO 7 .2 % < 400 0 CL 0.0 TO -0.04 10.0 TO 12.0 % 4.0 TO 7 .2 % < 400 0 RV & RW +0.50 TO -0.10 11.5 TO 12.5 % 3.7 TO 5.0 % < 400 0 AB +0.25 TO -0.06 11.5 TO 12.5 % 3.7 TO 5[...]

2.6 OPERATIN G INSTRUCTIONS 2.6.1 FAMILIARIZA TION WITH MANUAL(S) The operatin g instructions should be kept in the pocket in the boiler for F Series boilers, or adjacent to the boiler for all others. The user of the boiler must familiar ize himself with this manual and the burner manual for forced draft boilers to be sure he is prepared to operate[...]

CARE AND MA INTENANCE STEAM BOILERS CAUTION : • The boiler area should be kept free of combustibl e materials, gasolin e and other flammable liqui ds. • The boiler and venting system must be kept free of obstructions of the air louvers and draft hood relief openings. • The following procedures must be conducted as out line d to assure safe op[...]

CAUTION 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 suitable fa ce mask, goggles, protective gloves and garments when handling caustic chemicals. Do not permit the chemical to come into con[...]

3.3 SYSTEM CLEAN OUT Many boilers have been ruined with system contaminants such as pipe dope, cutting oil, metal shavings or chips and other debris which are left in the piping. If these contaminants are not removed, they will end up in the boiler. SYSTEM CLEANING PROCEDURE For steam systems, the boiler will need to be connected to the header util[...]

3.5 BOILER WATER TREATMENT PURPOSE OF WA TER TREATMENT Water treatment is required for satisfactory operation of the boiler. It must be devised to prevent depositing of scale and to prevent 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 wa[...]

3.7 SUGGESTED MA INTENANCE SCHEDULE DAILY 1. Make visual inspection of gauges, monitors, and indicators and record readings in boiler log. 2. Make visual check of instrument and equipment settings against factory reco mmended specifications. 3. Check operation of float type low water cutoffs to ensure control is functioning. The lower piping connec[...]

3.8 FLOAT-ACTUATED WATER LEVEL CONTROLS Inspect float type water level controls for proper operation. Visually inspect sight glasses for evidence of scale forming residues. Refer to section 3.9 for gauge glass maintenance. On closed steam heating systems, the float low water cutoff should be blown down by means of opening a blowdown valve on the lo[...]

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4.0 IDLE BOILER CARE AND LAY-UP GENERAL Corrosion damage to boilers is often the result o f improper lay-up during non-operating periods. Substantial damage can occur in only a few da ys in proper precautions are not taken. This damage is irreversible and will reduce boiler reliability, increase maintenance costs and eventually shorten the useful l[...]

lay-up. Raw city water is not recomme nded and should not be used. Prepare the chemical solution described in (1a) in a separate tank. Adhere to the safety precautions described in Section 3.2 of this manual. Add the concentrated lay-up solution to the bo iler during the time it is being filled. After the boiler is filled and the lay-up solution ha[...]

An alternate method is to completely dry a clean boil (by blowing hot dry air though the boiler) and then purge the air from the boiler and pressurize with 5 psig nitrogen. Be aware that all metal surfaces which are not completely dry are vulnerable to corrosion, part icularly if oxygen is present. 2. If a boiler has been down for repairs and is to[...]