Page 1 FreeStyle ® Wall Mount Gas-Fired Condensing Boilers Combi & Heat Only Models 80/120/155 Boiler Manual Low Lead Content Quick Start Guide Pages 3 & 4 Available in Combi or Heating Only models CSA - Low Lead Content only applies to the Combi model This manual must only be used by a qualiﬁed heating installer/service technician.
Page 2: Table Of Contents
1 Quick Start Guide — using default settings ..3 22 Wiring diagram — FS-80/120 Combi Ladder..52 2 Prepare boiler location ....6 22 Wiring diagram —...
Page 3: Quick Start Guide - Using Default Settings
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual Quick Start Guide — using default settings Figure 1 60-65 QUICK START GUIDE FreeStyle After you have completed the installation of the ® Boiler (Combi or Central Heating only models) by the instructions provided in the manual, pages 5-71 insure the following ﬁrst before you proceed:...
Page 4 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual Quick Start Guide — using default settings QUICK START GUIDE System start (continued) “Test Mode Operation” 1. To operate the boiler in test mode, press the CH “-” and “+”...
Page 5: Please Read Before Proceeding
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual Please read before proceeding — Read all instructions, including this Write in the CP number in the space provided on the Installation certiﬁcate on page 128 shown. given. When calling or writing about the boiler— Please Consider piping and installation when determining boiler location.
Page 6: Prepare Boiler Location
® FreeStyle boiler alone in boiler room FreeStyle® clearances around FreeStyle® boiler are at least equal to the SERVICE clearances shown in Figure 2, page 7. latest edition. 2. For spaces that DO NOT supply the minimum service clear- ances, provide two openings as shown in Figure 2, page 7.
Page 7 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 2 Prepare boiler location continued Clearances A Provide combustion air/ventilation openings per Figure 23, page 22 or as otherwise directed in this manual or by applicable codes. If the installation does not provide the minimum clearances,...
Page 8: Prepare Boiler
2 Prepare boiler location continued Air contamination air contamination problems. See Table 1 FreeStyle® boiler as combustion air. described in this manual. The air termination ﬁtting must be installed with the clearances and geometry relative to the vent outlet depicted in this manual to ensure that ﬂue products do not enter the air intake.
Page 9 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 3 Prepare boiler continued Figure 3 Wall-mounting requirements DO NOT attempt to attach the wall mount bracket using anchors or any means other than directly 14 inches-center to center of rubber...
Page 10 2. Drain boiler through drain valve (item 10). Rapid water ﬂow could cause injury. 1”NPT on FS-155). b. Two close nipples (¾”NPT on FS-80/120, 1”NPT on FS-155). the system piping. c. ¾” NPT pipe plug. d. Pressure/temperature gauge. e. ¾” NPT boiler drain valve.
Page 11 4. Pressure/temperature gauge, (ﬁeld supplied) by installer 5a. Reducing tee, NPT, ¾ ” x ¾” x ¼” on FS-80/120, NPT, 1 ” x 1” x ¼” on FS-155. 5b. Tee, NPT, ¾ ” x ¾ ” x ¾” on FS-80/120, NPT, 1 ” x 1” x ¾” on FS-155.
Page 12: Converting Boiler To Propane
Gasket Nitrile Rubber 167 x 63.5X3.53 NBR ® 3541F210 Label Gas Conversion FreeStyle 3541G190 Label FS-80 Rating Plate Conversion LP 550-142-854 Instructions Conversion Nat to LP Gas — For a boiler already P/N 640-000-025WT NG to Propane Gas Conversion Kit contents: 36602450 Venturi - 12.6 GPL 35105080 Gasket Nitrile Rubber 167 x 63.5X3.53 NBR...
Page 13 ﬁre) 1. Remove two (2) — FreeStyle® 80: 3.5” w.c.; — FreeStyle® 120: 3.5” w.c.; 2. Remove the one (1) screw holding control module in place — FreeStyle® 155: 3.5” w.c.
Page 14 (see Figure 16), re-insert three (3) Hex head screws to hold new venturi, tighten to hold securely in place. matches the boiler size (80, 120 or 155). 5. Reassemble gas pipe and new washer to the venturi ﬁtting,...
Page 15 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 4 Converting boiler to propane continued Inspect the gas pipe ﬁtting connections on the gas valve and new venturi (Item 3, Figure 15) check the The valve could be gas leak, resulting in severe personal injury or death.
Page 16: Gas Piping - Sizing Gas Lines
1020 1650 1. Pressure required at gas valve inlet pressure port: 1400 1130 boiler startup, while boiler is at high ﬁre): ® FreeStyle 80: 3.5” w.c. Figure 19 ® FreeStyle 120: 3.5” w.c. ® FreeStyle 155: 3.5” w.c. Nominal gas pressure: 7.0” w.c.
Page 17: Venting/Air Piping - General
When removing a boiler from an existing common vent system ® FreeStyle . When an existing boiler is replaced with ® a FreeStyle® boiler, the FreeStyle ® existing common vent. The FreeStyle boiler requires its own vent and air piping, as speciﬁed in this manual. This may cause a old common vent system.
Page 18 Maximum vent lengths apply for either 2” or 3” vent and air pipe. If using 2” pipe (FS-80/120 only), provide 3”x 2” reducers at boiler connections and at vent/air cap or at concentric terminations. Boilers will derate as vent/air pipe length increases —...
Page 19 DO NOT cover non-metallic vent pipe and ﬁttings is required. with thermal insulation. If using 2” piping (FS-80/120 only), where approved for the application, provide adapters for a 3” pipe material (mentioned above) connections and at the termina- tions, if required.
Page 20: Commonwealth Of Massachusetts Installations
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 7 Commonwealth of Massachusetts installations Commonwealth of Massachusetts — installed in every dwelling, building or structure used in not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and owned or operated by the Commonwealth and where the shall be satisﬁed:...
Page 21: Vent Termination Requirements
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 8 Vent termination requirements Figure 22 Part number 550-142-850/0716...
Page 22: Boiler Room Air Openings
OUNT GAS FIRED WATER BOILER Boiler Manual 9 Boiler room air openings ® FreeStyle Figure 23 ® FreeStyle FreeStyle ® are less than the recommended service clearances shown in Figure 2, page 7. Air openings FreeStyle FreeStyle ® ® boiler boiler...
Page 23: Direct Vent - Sidewall With Separate Pipes
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 10 DIRECT VENT — Sidewall with separate pipes Figure 24 Allowable vent/air pipe materials & lengths Use only the vent materials and kits listed in Figure 21, page 19 1. Locate the termination such that the total air piping and vent maximum length given in Figure 20, page 18.
Page 24 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 10 DIRECT VENT — Sidewall with separate pipes continued Figure 25 See notices on previous page. noncombustible construction, size the vent pipe hole at least 0.4” larger than the vent pipe diameter.
Page 25: Direct Vent - Sidewall Concentric
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 11 DIRECT VENT — Sidewall concentric Allowable vent/air pipe materials & lengths 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 21, page 19 speciﬁed.
Page 26 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 11 DIRECT VENT — (continued) Figure 28 See notices on previous page. Install termination — concentric pipes nations, on page 31. ensure the pipes butt correctly at both ends. Failure to properly assemble the concentric termination can result in ﬂue gas recirculation, causing possible severe personal...
Page 27: Direct Vent - Vertical With Separate Pipes
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 12 DIRECT VENT — Figure 30 Allowable vent/air pipe materials & lengths Use only the vent materials and kits listed in Figure 21, page 19. Provide pipe adapt- 1. Locate the terminations such that the total air piping will not exceed the maximum length given in Fig- ure 19, page 19.
Page 28 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 12 DIRECT VENT — (continued) Figure 31 See notices on previous page. close as desired to the air pipe outside diameter. 2. Vent pipe penetration: or noncombustible construction, size the vent pipe hole at least 0.4”...
Page 29: Direct Vent - Vertical Concentric
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 13 DIRECT VENT — Figure 32 Allowable vent/air pipe materials & lengths 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 21, page 19 speciﬁed.
Page 30 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 13 DIRECT VENT — (continued) See notices on previous page. Figure 33 a. Cut a clearance hole to clear the termination outside diameter as prescribed in the kit instructions. b. Insert a galvanized metal thimble in the vent pipe hole.
Page 31: Concentric Termination, Typical (Sidewall Or Vertical)
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 14 Concentric termination, typical (sidewall or vertical) Figure 35 Figure 35 Inner PVC pipe (vent) Bird screen Outer PVC pipe (air) Y ﬁtting Rain cap Finished assembly 1. Follow all instructions provided with the concentric 2.
Page 32: Vent And Air Piping And Boiler Connections
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 15 Vent and air piping and boiler connections Follow termination instructions Vent adapter in Figure 21, page 19. Installing vent and air piping For polypropylene applications, comply with any Vent...
Page 33 Boiler Manual 15 Vent and air piping and boiler connections (continued) Figure 40 (FS- 80/120 only) prevent possible damage to sealing gasket in vent pipe adapter. tip pen. 6. Insert pipe into adapter. Vent and Air adapters to be installed with test ports facing to 7.
Page 34 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 15 Vent and air piping and boiler connections (continued) Control selection for vent material To insure proper boiler operation (Combi and Heating Only boil- material. You MUST venting material that you installed other than PVC, in order to Quick Start Guide”...
Page 35: Install Water Piping
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 16 Install water piping Domestic Water Piping – Combi Boiler Figure 42 Hot Water Can Scald! states recommend domestic hot water tempera- When installing an automatic mixing valve, se- lection and installation must comply with valve washing, dish washing and other sanitizing needs will scald and cause injury.
Page 36 Boiler Manual 16 Install water piping (continued) Studies have indicated that dangerous bacteria reset circuit, set FreeStyle® control boiler limit at least 20°F less than the external manual reset limit (i.e., set FreeStyle® example). required by local codes. This boiler is NOT...
Page 37: Primary/Secondary System Piping
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping Expansion Tank Location System water piping methods Figure 45, page 38 expansion tank. It is highly recommended that you locate 1. Connect boiler to system only as shown in Figure 45, page 38.
Page 38 (continued) Figure 45 Piping to diaphragm (or bladder) expansion tank ® Figure 46 FreeStyle Pressure drop through 80/120/155 heat exchanger (graphs and table) (GPM) Total Loss - Ft. Boiler Piping Est. Head Loss - Recommended BOILER (Boiler + Near Boiler...
Page 39: Closed-Type Expansion Tank
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping (continued) Closed-type expansion tank: 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.
Page 40: Install Relief Valve
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping (continued) Install relief valve Figure 6, page 11). in the below. shown in illustrations in this manual. discharge line in a manner that will prevent possibility...
Page 41: Zone Valve Zoning - Primary/Secondary
2. The boiler and zone valves can also be operated by a Wiring the Indirect tank aquastat to the Heating Only zone controller. Controlling the Zones 1. The FreeStyle® control can be used to control space heating only, domestic beginning on page 51 Figure 48 1 FreeStyle®...
Page 42: Circulator Zoning - Primary/Secondary
Wiring the Indirect tank aquastat to the Heating Only Controlling the Zones 1. The FreeStyle® control can be used to control space heating only, (Applies to Figures 48, 49 & 50) ning on page 51 Add boiler and tank head loss for pump 2.
Page 43: Circulator Zoning - Multiple Temperature Zones With Primary/Secondary
Wiring the Indirect tank aquastat to the Heating Only 3. DHW Priority operation—The FreeStyle® control Controlling the Zones 1. The FreeStyle® control can be used to control space heating only, domestic priority. See page 65 domestic water heating only, or both.
Page 44: Multiple Boiler Installations
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 18 Multiple boiler installations FreeStyle Figure 51 ® Placing multiple boilers 1. Locate multiple boilers with spacings shown in Figure 51. local codes. ensure accessibility. 4. Unpack, assemble and mount boilers according to instructions in this manual.
Page 45 5 Expansion tank (diaphragm type) 15 System supply 6 System air eliminator 16 System return System automatic air vent per FreeStyle® 8 Pressure reducing valve 18 Purge/drain valve 9 Check valve or backﬂow preventer, as required by appli- cable codes...
Page 46 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 18 Multiple boiler installations (continued) When using a multiple-boiler control with lead boiler DHW tank piping with multiple rotation, it is recommended that the boiler connected to FreeStyle ® boilers...
Page 47: Install Condensate Line
Use materials approved by the authority having D1785, F441 or D2665. Cement and primer Figure 55 should have an overﬂow switch to prevent property FreeStyle® 80, FreeStyle® Free- Style® 155. 3. When sizing condensate pumps, make sure to include The condensate line must remain unob- ing in potential water damage to property.
Page 48: Gas Piping
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 20 Gas piping FreeStyle ® boilers are shipped ready to ﬁre natural gas ONLY. You must install the pro- to propane. See page 12. Failure to comply could result in severe personal injury, death or substantial property damage.
Page 49 1. Set up the boiler to operate at maximum rate as described in section “ Test mode” Figure 95, page 70. — FreeStyle® 80: 3.5” w.c.; 2. With the boiler operating at maximum rate check that the op- — FreeStyle® 120: 3.5” w.c.;...
Page 50: Field Wiring
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 21 Field wiring The installation must comply Wi r i n g m u s t b e N . E . C . with: National Electrical Code supplied with boiler must be...
Page 51 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 21 Field wiring (continued) Outdoor sensor uses the back connection block, see Figure 60, Item 138 Heating Only boiler. water circuit. thermostat wire 22 gauge). trol case. In order to access the connector you will have to control to enable you to rotate the control and access the above ground level.
Page 52: Wiring Diagram - Fs-80/120 Combi Ladder
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 22 Wiring diagram — FS-80/120 Combi Ladder FreeStyle Figure 66 ® NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local require- ments.
Page 53: Wiring Diagram - Fs-80/120 Combi Schematic
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 22 Wiring diagram — FS-80/120 Combi Schematic FreeStyle ® Part number 550-142-850/0716...
Page 54: Wiring Diagram - Fs-80/120 Heating Only Ladder
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 23 Wiring diagram — FS-80/120 Heating Only Ladder FreeStyle Figure 68 ® NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local requirements.
Page 55: Wiring Diagram - Fs-80/120 Heating Only Schematic
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 23 Wiring diagram — FS-80/120 Heating Only Schematic FreeStyle Figure 69 ® Part number 550-142-850/0716...
Page 56: Wiring Diagram - Fs-155 Combi Ladder
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 23 Wiring diagram — FS-155 Combi Ladder FreeStyle ® NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local require- ments. Room thermostat should...
Page 57: Wiring Diagram - Fs-155 Combi Schematic
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 23 Wiring diagram — FS-155 Combi Schematic FreeStyle ® Part number 550-142-850/0716...
Page 58: Wiring Diagram - Fs-155 Heating Only Ladder
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 23 Wiring diagram — FS-155 Heating Only Ladder FreeStyle ® NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local requirements. Room thermostat should...
Page 59: Wiring Diagram - Fs- 155 Heating Only Schematic
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 23 Wiring diagram — FS- 155 Heating Only Schematic FreeStyle ® Part number 550-142-850/0716...
Page 60: Controls And Operation
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 24 Controls and operation Control Introduction Thanks to the microprocessor control and adjustment system FreeStyle automatic. The system heating temperature is automatically on Natural gas or Liqueﬁed Petroleum (Propane) gas, generating governed by the control system.
Page 61 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 24 Controls and operation (continued) Central heating operation the radiator (Items 13 and 14 - Figure 74, page 60). The display indicates the actual Central Heating water temperature (Item 11 - Figure 74, page 60) and when the required temperature is reached “d2”...
Page 62 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 24 Controls and operation (continued) Ignition operation Ensure the power is on to the boiler Turning off Figure 74, page 60 On/Off button pcb is still powered, heating operation is disabled and the To totally isolate, close the gas cock before the boiler and disconnect electricity supply.
Page 63 Boiler Manual 24 Controls and operation (continued) Adjustments Figure 80 To set the system Heating temperature, use the CH buttons, “-” to reduce water setpoint “+” to increase water setpoint (Items 3 and 4 - Figure 74, page 60 Figure 81 To set the Domestic hot water temperature, use the DHW buttons, “-”...
Page 64 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 24 Controls and operation (continued) Adjustments Figure 82 Theory of Outdoor Reset Control space. ture. These scale ranges are related to the outdoor tem- radiation. - Figure 74, page 60 These “Outdoor Reset Control”...
Page 65: Dhw Settings (Combi Only)
FS-120 FS-155 Figure 86 Figure 88 Freestyle 80 - DHW PRODUCTION G.P.M. Freestyle 80 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100105 Delta T (ºF) Part number 550-142-850/0716...
Page 66: High Altitude
(b05) (b04) Freestyle 120 Figure 92 Delta T (ºF) 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100105 Figure 90 Model Ignition High Fire Freestyle 155 - DHW PRODUCTION...
Page 67: Startup
ﬂow is present. Close the zone isolation valves and proceed with the next zone. Follow this proce- dure until all zones are purged. Follow the same procedure FreeStyle® Gas Boilers. See Figure 153, page 113 7. Close the quick-ﬁll water valve and drain valve and remove the hose.
Page 68 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 27 Startup (continued) Freeze protection (if used) using the manual air vents located throughout the system. Follow these guidelines to prevent pos- system one at a time, beginning with lowest ﬂoor. Close vent when water squirts out.
Page 69: 6Wduwxs ² ¿Qdo Fkhfnv
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 28 6WDUWXS ² ¿QDO FKHFNV the external wiring. Check for gas leaks FreeStyle ® thermostat . This could cause terminals to 3-wire zone valves control damage. use a leak detector or smell near the ﬂoor and around 5.
Page 70 ❏ If boiler does not start correctly ing and vent piping are intact and correctly installed per this manual. plugged in? ❏ Read the instructions to adjust and set up the FreeStyle ® temperature above 200°F? control. ❏ ® FreeStyle control, and that it displays correctly.
Page 71 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 28 6WDUWXS ² ¿QDO FKHFNV (continued) ® FreeStyle Figure 96 Part number 550-142-850/0716...
Page 72 FreeStyle® boilers are shipped ready to ﬁre natural gas ONLY. c. Calculate gas input: Failure to comply could result in severe personal injury, death or substantial property damage.
Page 73 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 28 6WDUWXS ² ¿QDO FKHFNV (continued) Using a combustion analyzer check the CO values at low and high ﬁre. It should be within Setting the Air/Gas Ratio valve Figure 98 be below 0.2% or above 1%.
Page 74 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 28 6WDUWXS ² ¿QDO FKHFNV (continued) Re-check the Minimum Rate At Minimum Rate: to stabilize. Figure 100 - cup B) the minimum rate output ensuring the CO setting level has...
Page 75: KhfnRxwVwduwxs Yhul¿Fdwlrq
16, with boiler operating at ❏ high ﬁre, and no more than 13 inches (330 mm) w.c. with FreeStyle® boilers are shipped ready to ﬁre natural ❏ instructions in this manual to install the propane ❏...
Page 76: Annual Startup And General Maintenance
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 30 Annual startup and general maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped property damage. Figure 102 FreeStyle ® Monthly 6 months...
Page 77: Annual Startup
31 Annual startup HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS in addition to routine annual The FreeStyle® relevant seals; contain ceramic ﬁber materials that have been identiﬁed as carcinogenic, or possibly c. The operational (working) gas inlet pressure at maximum rate, as described on pages 49 and 73;...
Page 78 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 31 Annual startup (continued) Check ignition wiring The boiler should be inspected and started season, only by a qualiﬁed service technician. acceptable. the boiler designated in Figure 102, page 76 to ground terminal screw.
Page 79 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 31 Annual startup (continued) burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean 3. To access the burner, remove the heat exchanger cover 104.
Page 80 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 31 Annual startup (continued) Check boiler relief valve Reinstall jacket door after servicing scald potential. inside the boiler room. This is particularly important 2. Read page 40 appliances. tened could result in severe personal injury or death.
Page 81: Troubleshooting
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting ® FreeStyle the “ ” (page 128). Record the boiler size and CP to boiler. FreeStyle 2. Check the ® jacket). 3. See Figure 74, page 60 TS Flashing (parameter) Failure to adhere to these guide- Push heating –...
Page 82 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) Check ignition sequence Figure 105 HEAT DEMAND PRE-PUMP TIME PRE-PURGE TIME INTER-PURGE FOR INTER-PURGE FOR IGNITION IGNITION IGNITION DETECTION TIME A01 ATTEMPTS A06 ATTEMPTS GAS VALVE SAFETY TIME...
Page 83: Checking Temperature Sensors
Fuse located on rear of circuit board FreeStyle ® 80, 120 or 155. The ﬂame signal value must be at least 255 on high ﬁre FreeStyle ® 80, 120 or 155. , reading signal drops below this level, the FreeStyle ® control will at- tempt to correct by increasing the blower speed to increase ﬂame signal.
Page 84 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle ® Control diagnosis FreeStyle 1. The ® boiler control A” see ): to restore operation, press the RESET button (Item 6 - Figure 74, page 60 F”, see...
Page 85 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 109 (continued) Fault Code Fault Condition Correction &KHFN WKH UHJXODU JDV ÀRZ WR WKH ERLOHU DQG WKDW No burner ignition No gas the air has been eliminated from the pipes.
Page 86 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 110 (continued) Fault Code Fault Condition Correction Probe damaged Exhaust probe fault Check the wiring or replace the exhaust Wiring shorted probe Wiring disconnected...
Page 87 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 111 (continued) Blocking codes there is also an “F ® Table 4 FreeStyle The Exhaust gases temperature is too high The CH supply water temperature sensor 1 error...
Page 88 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 112 (continued) Display Condition FAULT 11 = CH return sensor out of normal operating range (short circuit or open circuit). If sensor goes outside the range, error will be generated.
Page 89 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 113 (continued) Display Condition FAULT 37 = Low water pressure error can be caused by the low water pressure in the central heating system. This can be GHWHFWHG LQ ZD\V YLD ORZ ZDWHU SUHVVXUH VZLWFK DQG YLD ZDWHU SUHVVXUH VHQVRU ZLWK D FRQ¿UPLQJ WLPH RI ...
Page 90 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 114 Conﬁguration mode The display starts with showing “ parameters; between “ ” and “b28 it is possible to adjust his value (not ﬂashing). The value is automatically saved.
Page 91 (not ﬂashing). The value is automatically saved. ® FreeStyle Figure 116 Parameter Description Default Note (60% - FS-120/80% - FS-80) Ignition level (%) 60 or 80 60% - FS-155) CH slope control (°F/min) Minimum Virtual set point (°F) CH OFF time (Min)
Page 92 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Parameter Description Default Note '+: RII PRGH '+: FRQ¿J DHW conf. dependent /HJLRQHOOD SURWHFWLRQ '+: FRQ¿J ZLWK VHQVRU /HJLRQHOOD SURWHFWLRQ '+: FRQ¿J ZLWK WKHUPRVWDW '+: RII PRGH '+: FRQ¿J ...
Page 93 Gas type type Freq. in DHW Freq. in CH Freq. in CH selection button Relay level (F/min) Off Time FS-80-N-C 1DW JDV FS-120-N-C 1DW JDV FS-155-N-C 1DW JDV FS-80-N-H 1DW JDV FS-120-N-H 1DW JDV FS-155-N-H...
Page 94 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 121 blinking Actual water pressure (psi) blinking Actual PWM modulating Pump (%) 0LQ 0D[ blinking Actual Step of Triac mod. mode (Num)
Page 95 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 123 (continued) System Parameters list (default settings) There are 4 basic conﬁgurations within the DHW mode, selected by parameter DHW conﬁguration (see Parameters list, Num.
Page 96 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 124 (continued) Category Description Num. Address Description High Value '+: FRQ¿J 36,1 ML – 8104 CH supply for CH pump over-run OFF °F '+: FRQ¿J ...
Page 97 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 125 (continued) Category Description Num. Address Description High Value '+: FRQ¿J 42,2 ML – 810A DHW set point limit – LOW °F '+: FRQ¿J 43,2 CL5 –...
Page 98 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 126 (continued) Category Description Num. Address Description High Value '+: FRQ¿J CL5 – 066E DHW P factor '+: FRQ¿J 10,4 CL5 – 0691 DHW I factor '+: FRQ¿J ...
Page 99 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle (continued) Category Description Num. Address Description High Value Central Heating CL5 – 059D CH pump selection Central Heating CL5 – 0592 CH slope control °F/min Central Heating CL5 –...
Page 100 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 128 (continued) Category Description Num. Address Description High Value History ML – 8061 Total num. of hours with power supply ON - LSB History ML –...
Page 101 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 129 (continued) Category Description Num. Address Description High Value Flame current supervi- ML – 80D5 Flame current on level1 offset sion Flame current supervi- ML –...
Page 102 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) ® FreeStyle Figure 130 (continued) Some informations can be accessed with a communication package running on the PC. Category Description Num. Address Description Boiler CL4 – A532 CH supply sensor1 temperature °F *10...
Page 103: Maintenance
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance Clean condensate trap Disconnect power 1. See Figure 131. 2. Disconnect top cleanout cap nut that secures the trap body to Electrical shock hazard — Discon- the boiler condensate connection.
Page 104 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Figure 133 Figure 135 2. Remove two (2) Phillips head screws securing the ignition electrode to the boiler heat exchanger. Use care when removing and handling igniter.
Page 105 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Figure 139 Inspect the burner exterior. It must be in good condition, with no visible damage. ing removal. Replace the gasket with a new one during reassembly.
Page 106 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Inspect and clean the heat exchanger Wait until heat exchanger/boiler is cooled down severe injury. 1. See Figures 140 and 144. 2. Use a 10mm wrench or socket to remove the ﬁve (5) nuts that Figure 142 secure the burner cover plate to the heat exchanger.
Page 107 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Procedure For Cleaning Of Internal Heat Figure 144 Exchanger Circuit scale, sludge, metal oxides and, in low temperature systems, also biomass in the heat exchanger water circuit.
Page 108 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Actions For Cleaning Of Heat Exchanger Procedure for chemical cleaning of DHW circuit Water Circuit struction booklet. Chemical cleaning and maintenance must be carried out by pro- not carry out any operation on the sealed control parts.
Page 109 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Hot Water Can Scald! 130°F or less. Actions for chemical cleaning of When installing an automatic mixing valve, selection Domestic hot water circuit washing, dish washing and other sanitizing needs will scald and cause injury.
Page 110 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Figure 149 placed next to the CH return (5), see Figure 144. Release Heat Exchanger pressure in the boiler by to heat exchanger return. The direction of arrows on heat exchanger.
Page 111 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Figure 151 20. Reconnect the unit to the electrical power supply us- turn it ON. DHW Outlet DHW Inlet (diverter valve) disposal. 13. The cleaned brazed plate heat exchanger can now be installed.
Page 112: Replacement Parts
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts REPLACEMENT PART NUMBERS found in this manual and in Williamson- Thermoﬂo Boilers and Controls Repair Parts Lists. Obtain parts only through Williamson-Thermoﬂo Replacement parts must be purchased through a local Williamson-...
Page 113 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) Figure 153 M&G Simpson-Duravent PolyPro SIDEWALL concentric vent/air kit (color: white) Antifreeze, Sentinel X500 ... 592-900-029WT 2”...
Page 114 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) ® FreeStyle Figure 154 Item Name Part Number Jacket door 640-000-067WT Jacket left side 640-000-065WT Jacket right side 640-000-066WT Part number 550-142-850/0716...
Page 115 Control module assembly 640-000-003WT Control module display cover 640-000-004WT Pressure-Temperature assembly 640-000-006WT Wire harness assembly - Combi - 80/120 640-000-005WT Wire harness assembly - Combi - 155 640-000-085WT Wire harness assembly - Heating Only 640-000-053WT Blower wiring adapter - Heating Only - 155...
Page 116 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) ® FreeStyle Figure 156 Combi Model Item Name Part Number 640-000-008WT Heat Exchanger 640-000-009WT Flue Sensor Temperature 640-000-011WT Blower Assembly 640-000-020WT Blower Gasket 640-000-021WT Ignitor 640-000-109WT...
Page 117 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) ® FreeStyle Combi ) continued Part number 550-142-850/0716...
Page 118 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) ® FreeStyle Figure 158 Heating Only Model Item Name Part Number 640-000-008WT Heat Exchanger 640-000-009WT Flue Sensor Temperature 640-000-011WT Blower Assembly 640-000-020WT Blower Gasket 640-000-021WT Ignitor...
Page 119 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) ® FreeStyle Figure 159 Heating Only ) continued Part number 550-142-850/0716...
Page 120 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) ® FreeStyle Figure 160 Combi Item Name Part Number Heat Exchanger 640-000-080WT Flue Sensor Temperature 640-000-011WT Blower Assembly 640-000-081WT Blower Gasket 640-000-021WT Ignitor 640-000-109WT Central Heat Exchanger Insulation...
Page 121 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) ® FreeStyle Figure 161 Combi ) continued Part number 550-142-850/0716...
Page 122 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) ® FreeStyle Figure 162 Heating Only Item Name Part Number Heat Exchanger 640-000-080WT Flue Sensor Temperature 640-000-011WT Blower Assembly 640-000-081WT Blower Gasket 640-000-021WT Ignitor 640-000-109WT Central Heat Exchanger Insulation...
Page 123 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) ® FreeStyle Figure 163 Heating Only ) continued Part number 550-142-850/0716...
Page 124: Dimensions And Connections Data
® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 35 Dimensions and connections data ® FreeStyle Figure 164 Part number 550-142-850/0716...
Page 125 ® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 35 Dimensions and connections data ® FreeStyle Figure 165 Part number 550-142-850/0716...
Page 126: Engineering Data
15.0 FS-155 Heating Only amps total. FreeStyle® 80 or 120 vent/air pipes can be either 2” or 3” pipe. FreeStyle® 155 is 3” only. through the piping. See Figure 167, page 127 FreeStyle® . Install and terminate vents as described in vent/air installation instructions in this manual.
Page 127: Ratings
÷ 100. NOTE that only Heating Capacity and FreeStyle® 80 or 120 vent/air pipes can only applies be either 2” or 3”. FreeStyle® 155 is 3” to the Combi boiler models. only. 3 Net ratings are based on net installed be sweep elbows, NOT short-radius elbows.
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® — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 38 ,QVWDOODWLRQ DQG 6HUYLFH &HUWL¿FDWH Boiler Start-Up Data FreeStyle Boiler Model / Series ® ________ / Series ____ Date installed ________________ # +LJK ¿UH BBBBBB /RZ ¿UH BBBBBB Part Number ____________...

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