Freestyle 80 Manual 

Text of Freestyle 80 User Guide:

• Freestyle 80, Part number 550-142-850/0716 77 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 31 Annual startup HANDLING CERAMIC FIBER MATERIALS 2%-/6).'"52.%2'!3+%4OR #/6%20,!4%).35,!4)/. The FreeStyle®HEATEXCHANGERREFRACTORY contain ceramic fiber materials that have been identified as carcinogenic, or possibly carcinogenic, to humans). Ceramic fibers can be converted to cristobalite in very high temperature applications.  4HE)NTERNATIONAL!GENCYFOR2ESEARCHON #ANCER)!2#HAS CONCLUDEDh#RYSTAL- LINESILICAINHALEDINTHEFORMOF�

• Freestyle 80, Part number 550-142-850/0716 67 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 27 Startup 5SETHECORRECTAMOUNTOFANTIFREEZE 1. $ETERMINETHE FREEZING TEMPERATURENEEDEDTOPROTECT against lowest likely temperature the system water will en- counter). 2. &INDTHEANTIFREEZECONCENTRATIONBYVOLUMENEEDEDFORTHIS TEMPERATUREFROMTHEANTIFREEZEMANUFACTURERSDATAONTHE ANTIFREEZECONTAINER 3. !DDUPTHEVOLUMEGALLONS�

• Freestyle 80, Figure 50 #IRCULATORZONINGWITHHIGHANDLOWTEMPERATURE HEATINGZONES Part number 550-142-850/0716 43 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 17 Primary/Secondary System Piping (continued) Circulator zoning – Multiple temperature zones with primary/ secondary (Shown with optional DHW piping) See Figure 50. 1. 4HISCONlGURATIONISFORCIRCULATORZONEDSYSTEMSWITH high- and low- temperature heating zones using a BOILERLOOPCONNECTEDASASECONDARYCIRCUITOFFOFAPRI- mary system loop. Sys

• Freestyle 80, Figure 54 #ONDENSATETRAPASSEMBLY Figure 55 #ONDENSATETRAPCONNECTION Figure 56 &ILLINGTHECONDENSATETRAPASSEMBLY Part number 550-142-850/0716 47 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual Prepare condensate trap assembly 4HISBOILER ISEQUIPPEDWITHAN INTERNALAIRTRAPTODRAIN OFFCON- densate. 1. RemovETHECONDENSATETRAPKITFROMTHEACCESSORIESBAG 2. See Figures 54, 55 and 56. The figures below shows the installa- TIONOFTHECONDENSATETRAPCONNECTIONS 3. Install the inspection coupling A and gask

• Freestyle 80, Check inhibitor concentration annually 1. 4ESTTHEP(OFASAMPLEOFSYSTEMWATERATLEASTANNUALLY 4HEP(OFTHEWATERMIXTUREMUSTBEBETWEENAND (Or use the Sentinel inhibitor test kit to check concentra- tion.) 2. )FP(ISOUTSIDETHISRANGEORINHIBITORTESTKITINDICATES LOWLEVELTHEINHIBITORLEVELMAYNOTBESUFlCIENTTOPRE- vent corrosion. 3. 4ESTANTIFREEZECONCENTRATION  4EST ANTIFREEZECONCENTRATION AT LEAST ANNUALLY )FCONCENTRATIONISLO

• Freestyle 80, Part number 550-142-850/0716 107 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual )GNITOR 33 Maintenance (continued) Procedure For Cleaning Of Internal Heat Exchanger Circuit 4HISPROCEDUREISINTENDEDASAGUIDELINEFORACORRECTRESTORATION OFTHEFUNCTIONALITYOFTHEBOILERASARESULTOFOPERATIONWITH UNTREATEDWATERVERYHARDWATERFEEDINGCONDITIONSDEBRISLIME scale, sludge, metal oxides and, in low temperature systems, also biomass in the heat exchanger

• Figure 30 3EPARATEPIPESVERTICALTERMINATION 4ERMINATEVENTANDAIRPIPESSUCHTHAT A !)2).4!+%)3!4,%!34INCHESBELOWVENTOUTLET B !)2).4!+%IS NO FURTHER than 12 inches away center to center C !)2 ).4!+% )3 !4 ,%!34  INCHESABOVEROOF OR SNOW LINE KEEP�

• Freestyle 80, Part number 550-142-850/0716 22 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 9 Boiler room air openings Figure 23 #OMBUSTIONANDVENTILATIONAIROPENINGSFORFreeStyle ® $IRECT6ENTINSTALLATIONS0ROVISIONSFORCOMBUSTION ANDVENTILATIONAIRTOBENACCORDANCEWITHTHESECTIONh!IRFOR#OMBUSTIONAND6ENTILATIONvOFTHE.ATIONAL&UEL 'AS#ODE!.3):.&0!ORAPPLICABLEPROVISIONSOFTHELOCALBUILDINGCODES�

• Freestyle 80, Part number 550-142-850/0716 97 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 32 Troubleshooting(continued) Category %PROMPARAMETERS 5NIT 2ANGE $EF Description Num. Address Description Low High Value  42,2 ML – 810A DHW set point limit – LOW °F 50 104 50  43,2 CL5 – 1E76 DHW set point limit – HIGH °F 104 158 149  44,2 CL5 – 05F4 DHW user set point – Default value °

• Freestyle 80, Part number 550-142-850/0716 112 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual Figure 1520ROPANECONVERSIONKITSANDINSTRUCTIONS Boiler model Kit PARTNUMBER )NSTALLATION INSTRUCTIONS &3.' 640-000-022WT 3EEPAGE &3,0 640-000-024WT &3.' 640-000-023WT &3,0 640-000-025WT &3.' 640-000-082WT &3,0 640-000-083WT REPLACEMENT PART NUMBERS 7ILLIAMSON4HERMOmOPART

• Freestyle 80, Part number 550-142-850/0716 17 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 6 Venting/air piping — general Do not install the FreeStyle ® boiler into a com- mon vent with any other appliance. This will CAUSEmUEGASSPILLAGEORAPPLIANCEMALFUNCTION resulting in possible severe personal injury, death or substantial property damage. Existing common vent systems may be too large FORTHEAPPLIANCESREMAININGCONNECTEDAFTERTHE existing boiler is removed.  &AILURE TOFOLLOWALLINSTRUCTIONSCANRESU

• Freestyle 80, Part number 550-142-850/0716 101 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 32 Troubleshooting(continued) Category %PROMPARAMETERS 5NIT 2ANGE $EF Description Num. Address Description Low High Value Flame current supervi- sion 142 ML – 80D5 Flame current on level1 offset ADC 0 255 3 Flame current supervi- sion 143 ML – 80DB Flame current on level2 offset ADC 0 255 0 Flame current supervi- sion 144 ML – 8112 Flame current off level offset ADC 0 255 20 System 145 ML – 8134 High altitude & Chimney length selection Num 0 2 0 System 146 ML – 8131 Pre-purge time between A01 attempts Min 0 60 0 System 147 ML – 80D6 Pump pro

• Freestyle 80, Part number 550-142-850/0716 39 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual &IGURE0IPINGTOCLOSEDTYPEEXPANSIONTANK 17 Primary/Secondary System Piping (continued) Closed-type expansion tank:  $/./4USEACLOSEDTYPETANKIFCONNECTING to a water heater that is equipped with an au- tomatic air vent. Figure 47, shows suggested piping when using a closed-type expansion tank, in which the air is directly in contact with tank water. #ONNECTPIPINGvORÐvFROMTHEAIRSEPARATOROUTLET

• Freestyle 80, Figure 100Offset aDJUSTMENTSCREWnn /.,9FORUSEBYAQUALIlEDTECHNICIANUSING CALIBRATEDCOMBUSTIONTESTINSTRUMENTS Part number 550-142-850/0716 74 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual .ATURAL'AS!CCEPTABLE#OMBUSTION2ANGE -INIMUM2ATEAFTERMINUTESFROMCOLD Boiler Model CO/(PPM) CO 2 NG % CO 2 LP % &3 20  n   n  &3 20  n   n  &3 7 �

• Figure 25 -ULTIPLESEPARATEPIPESSIDEWALLTERMINATIONS MAINTAINVERTICALSPACINGBETWEENVENTANDAIR lTTINGSSHOWNIN&IGUREPAGE. Figure 26 3IDEWALLTERMINATIONASSEMBLYUSING SEPARATEPIPES See notices on previous page. Part number 550-142-850/0716 24 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOI

• Final checks before lighting the boiler ❏ /PENANYONOFFVALVESBETWEENBOILERANDTHESYSTEMS ❏ 6ERIFYTHATTHEREARENOLEAKSOFTHEGASSYSTEM ❏ 6ERIFY THAT THEBOILERAND SYSTEM AREFULL OF WATERAND ALL SYSTEMCOMPONENTSARECORRECTLYSETFOROPERATION ❏ 6ERIFY�

• Freestyle 80, Figure 53 0IPINGLAYOUTTYPICALPIPINGFORMULTIPLEBOILERSBOILERSYSTEMSHOWNWITH$(7STORAGEHEATERSGROUPEDAS ZONEINSECONDARYLOOPOFFPRIMARYSYSTEMLOOP(EATING/NLY Part number 550-142-850/0716 46 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual DHW tank piping with multiple FreeStyle ® boilers DHW direct connection—single tank 1. )F"45(OUTPUTOFASINGLEBOILERISSUFlCIENTFORTHE DHW tank/demand, pipe the indirect water heater to th

• Part number 550-142-850/0716 65 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 25 DHW Settings (Combi Only) DHW SETTINGS 1. 4HE$(73%44).'3MENUSAREFORSETTINGCONTROLOPERA- tion during DHW operation. The settings apply ONLY to $(7 :ONE 2. )F$(7IS USEDTHESETTINGSFORCONTROLOPERATIONDURING $(7CALLS�

• Freestyle 80, Part number 550-142-850/0716 85 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 32 Troubleshooting(continued) Figure 1094ROUBLESHOOTINGSUGGESTIONSFORFreeStyle ® BOILERS&AULTDISPLAYSANDDIAGNOSTICS(continued) Fault Code Fault Condition Correction A01 No burner ignition No gas  the air has been eliminated from the pipes. Ignition/detec

• Freestyle 80, Part number 550-142-850/0716 59 FreeStyle ® WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual 23 Wiring diagram — FS- 155 Heating Only Schematic &IGURE FreeStyle® (EATING/NLY3CHEMATIC7IRING$IAGRAM Legend 16 Fan 32 Central heating pump (not included) 44 Gas valve 72 Room thermostat (optional) 81 Ignition electrode 104(1) Fuse 3.15A 104(1) Fuse 630mA 114 Water pressure switch 130 DHW Pump (not included) 138 Out

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