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Williamson-Thermoflo FreeStyle 2 Series Manual

Wall mount gas-fired condensing boilers combi & heat only models
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Low Lead Content
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 qualifi ed heating installer/service technician. Failure to comply could result in
severe personal injury, death or substantial property damage.
FreeStyle
Wall Mount Gas-Fired
Condensing Boilers
Combi & Heat Only Models
80/120/155 –
Boiler Manual
Series 2
Quick Start
Guide
Pages 73 & 74
Part number 550-142-950/0919

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Summary of Contents for Williamson-Thermoflo FreeStyle 2 Series

  • Page 1 FreeStyle Wall Mount Gas-Fired Condensing Boilers Combi & Heat Only Models Series 2 80/120/155 – Boiler Manual Low Lead Content Quick Start Guide Pages 73 & 74 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 qualifi...

  • Page 2: Table Of Contents

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual Contents Page 21 Gas piping ..... . . 50 1 Please read before proceeding .

  • Page 3: Please Read Before Proceeding

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 1 Please read before proceeding — Read all instructions, including this Write in the Consumer Protection (CP) number in the space provided on the Installation certificate on page 136 given.

  • Page 4: Prepare Boiler Location

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 2 Prepare boiler location Codes & checklist Installations must comply with: Locate or protect the boiler so it cannot be damaged by a moving vehicle. Local, state, provincial, and national codes, laws, regulations and ordinances.
  • Page 5 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 2 Prepare boiler location continued Clearances A Provide combustion air/ventilation openings per Figure 23, page 20 or as otherwise directed in this manual or by applicable codes. If the installation does not provide the minimum clearances, Provide clearances from then the enclosure MUST HAVE air openings located per Figure 2, combustible materials —...

  • Page 6: Prepare Boiler

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 2 Prepare boiler location continued Air contamination air contamination problems. air intake 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 7 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 3 Prepare boiler continued Wall-mounting requirements Install the wall-mount bracket 1. Locate the studs — must be on 16-inch centers. See previ- using anchors or any means other than directly securing to the wall studs (or equivalent wood 2.
  • Page 8 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 3 Prepare boiler continued Hydrostatic pressure test Fill and pressure test 1. See Figure 5, page 9, (item 8 and 9) to catch water drippings. slightly. Leave top isolation valve item 8 open. .
  • Page 9 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 3 Prepare boiler continued Figure 5 Figure 6 see legend below) (see legend below) (Combi boiler shown) 1. Boiler supply (outlet) connection, (male, 1” NPT 2. Boiler return (inlet) connection, (male, 1” NPT Recommend Near Boiler Piping to be 1-1/4”...

  • Page 10: Converting Boiler To Propane

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 4 Converting boiler to propane Prepare boiler for propane (if required) FreeStyle ® 80/120/155 P/N 640-000-024WT NG to Propane Gas Conversion Kit contents: 36602430 Venturi - 10.6 GPL Propane operation 35105080 Gasket Nitrile Rubber 167 x 63.5X3.53 NBR 3541F210...
  • Page 11 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 4 Converting boiler to propane continued Figure 9 1. Contact propane gas supplier to size piping, tank and install requirements w.c. maximum pressure. For natural gas or propane, the pressure required at gas valve inlet ances are in operation): startup, while boiler is at high fire) 1.
  • Page 12 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 4 Converting boiler to propane continued Figure 12, Figures 13, 14, 15. 16 and 17 Figure 12, Item 6. Control panel (page 13) Hex head screws Figure 12 “O” Ring Washer Figure 14 5.
  • Page 13 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 4 Converting boiler to propane continued 12. Using a combustion analyzer insert probe into the flue test Figure 16 point, check that the CO content in the exhaust, with the boil- er operating at max.

  • Page 14: Gas Piping - Sizing Gas Lines

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 5 Gas piping — sizing gas lines Figure 18 enough to provide gas to all connected appliances. Natural Gas: total feet ½” ¾” 1” 1¼” 1½” 2” 2½” accordance with Figure 18 and Figure 19. 1050 1600 3050...

  • Page 15: Venting/Air Piping - General

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 6 Venting/air piping — general 4. Place in operation the appliance being inspected. Follow ance will operate continuously. sizing to approach the minimum size as determined using the ® Do not install the FreeStyle boiler into a com-...
  • Page 16 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 6 Venting/air piping — general continued Figure 20 Venting and air piping — DIRECT VENT ONLY The table below lists the acceptable vent/air pipe terminations described in this manual. Follow all instructions provided to install the vent/air system.
  • Page 17 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 6 Venting/air piping — general continued Figure 21 Vent and air piping materials see Figure 164, page 121 for part/kit numbers) Material United States PVC schedule 40 (Note 1) ANSI/ASTM D1785 Vent or air pipe PVC-DWV schedule 40...

  • Page 18: Commonwealth Of Massachusetts Installations

    FreeStyle Series 2 wall mount 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: TORS...

  • Page 19: Vent Termination Requirements

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 8 Vent termination requirements Figure 22 The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance from adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edition.

  • Page 20: Boiler Room Air Openings

    FreeStyle Series 2 wall mount 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 1, page 5. Air openings FreeStyle FreeStyle ® ®...

  • Page 21: Direct Vent - Sidewall With Separate Pipes

    FreeStyle Series 2 wall mount 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 17 1.
  • Page 22 FreeStyle Series 2 wall mount 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. b.

  • Page 23: Direct Vent - Sidewall Concentric

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 11 DIRECT VENT — Sidewall concentric Figure 27 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 17 specifi...
  • Page 24 FreeStyle Series 2 wall mount 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 injury or death.

  • Page 25: Direct Vent - Vertical With Separate Pipes

    FreeStyle Series 2 wall mount 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 17 . Provide pipe adapt- Locate the terminations such that the total air piping and exceed the maximum length given in Figure 20, page 16 .
  • Page 26 FreeStyle Series 2 wall mount 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. or noncombustible construction, size the vent pipe hole at least 0.4” larger than the vent pipe diameter. b.

  • Page 27: Direct Vent - Vertical Concentric

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 13 DIRECT VENT — Figure 32 Allowable vent/air pipe materials & lengths The concentric termination kit must be purchased sepa- rately. Use only the vent materials and kits listed in Figure 21, page 17 specifi...
  • Page 28 FreeStyle Series 2 wall mount 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.

  • Page 29: Direct Vent - Vertical Vent /Sidewall Air

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 14 DIRECT VENT — Figure 35 Use only the vent materials and kits listed in Fig- ure 21, page 17 1. Locate the terminations such that the total air pip- tion will not exceed the maximum length given in Figure 20, page 16 .
  • Page 30 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 14 DIRECT VENT — (continued) Figure 36 adjacent appliance terminations. guidelines. 3. The air piping must terminate in a down-turned elbow as shown in Figure 37. Figure 37 unless grade or snow line.

  • Page 31: Concentric Termination, Typical (Sidewall Or Vertical)

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 15 Concentric termination, typical (sidewall or vertical) Figure 38 Figure 38 Rain cap Finished assembly 1. Follow all instructions provided with the concentric 2. See Figure 38 termination assembly. not included with the kit).

  • Page 32: Vent And Air Piping And Boiler Connections

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 16 Vent and air piping and boiler connections Figure 40 Follow termination instructions Vent adapter in Figure 21, page 17. Installing vent and air piping For polypropylene applications, comply with any Vent additional requirements in the vent system manu- gasket...
  • Page 33 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 16 Vent and air piping and boiler connections (continued) Figure 43 prevent possible damage to sealing gasket in vent pipe adapter. tip pen. 6. Insert pipe into adapter. 7. Slide pipe down until the 2¼-inch mark is reached. Vent and Air adapters to be installed with test ports facing to front of boiler.
  • Page 34 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 16 Vent and air piping and boiler connections (continued) Control selection for vent material steel. Perform at start-up final checks “b22” parameter PVC solid core, ........Select: “1” Venting Material Change “b22”...

  • Page 35: Install Water Piping

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 17 Install water piping Domestic Water Piping – Combi Boiler Hot Water Can Scald! box, page 42 states recommend domestic hot water tempera- automatic mixing valve boiler model). When installing an selection and installation must comply with valve Figure 45 washing, dish washing and other sanitizing needs...
  • Page 36 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 17 Install water piping (continued) General piping information The control uses temperature sensors to provide both high limit protection and modulating temperature control. . Some codes/ jurisdictions may require additional external Figure 46 protection.

  • Page 37: Recirculation (If Used)

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 17 Install water piping (continued) 2. The circulator cannot run continuously as bypass through Figure 47 the mixing valve will eventually allow the temperature on the piping to climb to the water heater temperature during draw periods.
  • Page 38 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 17 Install water piping (continued) Figure 48 Part number 550-142-950/0919...

  • Page 39: Primary/Secondary System Piping

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 18 Primary/Secondary System Piping Expansion Tank Location System water piping methods Figure 51, page 40 tank. It is highly recommended that you locate the air separator and expansion tank as shown in the suggested piping drawings on pages 39 - 41.
  • Page 40 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 18 Primary/Secondary System Piping (continued) Figure 51 Figure 52 FreeStyle (GPM) Total Loss - Ft. Boiler Piping Est. Head Loss - Recommended BOILER (Boiler + Near Boiler Boiler Head Ft.

  • Page 41: Closed-Type Expansion Tank

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 18 Primary/Secondary System Piping (continued) Closed-type expansion tank: Figure 53 a water heater that is equipped with an automatic air vent. Figure 53, shows suggested piping when using a closed-type expansion tank, in which the air is directly in contact with tank water.

  • Page 42: Install Relief Valve

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 18 Primary/Secondary System Piping (continued) Install relief valve ” x 1 ” x ¾” -1/4 -1/4 Figure 5, page 9). in the below. shown in illustrations in this manual. discharge line in a manner that will prevent possibility Discharge line must be as short as possible and be the same size as the valve discharge connection throughout...

  • Page 43: Zone Valve Zoning - Primary/Secondary

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 18 Primary/Secondary System Piping (continued) Zone Valve zoning – primary/secondary Figure 54 (Shown with optional DHW piping) See Figure 54. loop. Systems whose flow characteristics do not comply with those listed in Figure 51, page 40 must pipe the boiler loop as a secondary circuit as show.

  • Page 44: Circulator Zoning - Primary/Secondary

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 18 Primary/Secondary System Piping (continued) Figure 55 Circulator zoning – primary/secondary (Shown with optional DHW piping) See Figure 55. loop. Systems zoned with circulators must pipe the boiler loop as a secondary circuit as show.

  • Page 45: Circulator Zoning - Multiple Temperature Zones With

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 18 Primary/Secondary System Piping (continued) Figure 56 Circulator zoning – Multiple temperature zones with primary/ secondary (Shown with optional DHW piping) See Figure 56 high- and low- temperature heating zones using a mary system loop.

  • Page 46: Multiple Boiler Installations

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 19 Multiple boiler installations ® FreeStyle Figure 57 Placing multiple boilers 1. Locate multiple boilers with spacings shown in Figure 57. local codes. ensure accessibility. 4. Unpack, assemble and mount boilers according to instructions in this manual.
  • Page 47 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 19 Multiple boiler installations (continued) ® FreeStyle Figure 58 Legend for Figure 58 1 Flow/check valve 10 Cold water supply 11 Supply water temperature control (when used). 2 Isolation valves (when used) 3 Cap header).
  • Page 48 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 19 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 the DHW tank is always set as the last boiler to operate in the sequence so that space heat can be maintained...

  • Page 49: Install Condensate Line

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 20 Install condensate line Figure 62 Prepare condensate trap assembly densate. 1. Remov 2. See Figures 60, 61 and 62. The figures below shows the installa- 3. Install the inspection coupling and gasket as shown.

  • Page 50: Gas Piping

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 21 Gas piping Figure 63 FreeStyle ® boilers are shipped ready to fire to propane. See page 10. Failure to comply could result in severe personal injury, death or substantial property damage. Union or Coupling must be used.
  • Page 51 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 21 Gas piping (continued) Measure the gas rate 1. See page 14 For natural gas or liquefied petroleum (propane) gas, the pres- gas pressure when all gas appliances are in operation): 1.

  • Page 52: Field Wiring

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 22 Field wiring The installation must comply HAZARD supplied with boiler must be and any other national, state, ply at service entrance panel replaced, use only type 105 °C provincial or local codes or regulations.
  • Page 53 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 22 Field wiring (continued) Outdoor sensor uses the back connection block, see Figure 66, Item 138 Heating Only boiler. thermostat wire 22 gauge). water circuit. trol case. In order to access the connector you will have to above ground level.

  • Page 54: Wiring Diagram - Fs-80/120 Combi Ladder

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 23 Wiring diagram — FS-80/120 Combi Ladder ® FreeStyle Figure 72 NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local requirements. Room thermostat should be a dry contact type and should draw power from the control board:...

  • Page 55: Wiring Diagram - Fs-80/120 Combi Schematic

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 23 Wiring diagram — FS-80/120 Combi Schematic ® FreeStyle Figure 73 Part number 550-142-950/0919...

  • Page 56: Wiring Diagram - Fs-80/120 Heating Only Ladder

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 24 Wiring diagram — FS-80/120 Heating Only Ladder FreeStyle Figure 74 ® NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local requirements.

  • Page 57: Wiring Diagram - Fs-80/120 Heating Only Schematic

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 24 Wiring diagram — FS-80/120 Heating Only Schematic ® FreeStyle Figure 75 Part number 550-142-950/0919...

  • Page 58: Wiring Diagram - Fs-155 Combi Ladder

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 25 Wiring diagram — FS-155 Combi Ladder ® FreeStyle Figure 76 NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local requirements. Room thermostat should be a dry contact type and should draw power from the control board:...

  • Page 59: Wiring Diagram - Fs-155 Combi Schematic

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 25 Wiring diagram — FS-155 Combi Schematic ® FreeStyle Figure 77 Part number 550-142-950/0919...

  • Page 60: Wiring Diagram - Fs-155 Heating Only Ladder

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 26 Wiring diagram — FS-155 Heating Only Ladder ® FreeStyle Figure 78 NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local requirements. Room thermostat should be a dry contact type and should draw power from the control...

  • Page 61: Wiring Diagram - Fs- 155 Heating Only Schematic

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 26 Wiring diagram — FS- 155 Heating Only Schematic ® FreeStyle Figure 79 Part number 550-142-950/0919...

  • Page 62: Controls And Operation

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 27 Controls and operation Control Introduction ® FreeStyle Thanks to the microprocessor control and adjustment system automatic. The system heating temperature is automatically extremely low emissions. governed by the control system. The boiler is constructed with a stainless steel heat exchanger operating status and it is easily possible to obtain and adjust problems associated with the boiler are immediately signalled by...
  • Page 63 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 27 Controls and operation (continued) Central heating operation the radiator (Items 12 and 13 - Figure 80, page 62). The display indicates the actual Central Heating water temperature (Item 10 - Figure 80, page 62) and when the required temperature is reached “d2”...
  • Page 64 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 27 Controls and operation (continued) Initial power up mode Figure 84 Software version For the fi rst 300 seconds, the display shows FH When the FH Turning off Figure 80, page 62 Figure 85 On/Off button eco”/power button, the con-...
  • Page 65 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 27 Controls and operation (continued) Adjustments Figure 86 To set the system Heating temperature, use the CH buttons, “-” to reduce water setpoint “+” to increase water setpoint (Items 3 and 4 - Figure 80, page 62 Figure 87 To set the Domestic hot water temperature, use the DHW buttons, “-”...
  • Page 66 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 27 Controls and operation (continued) Adjustments for - Heating Only Boilers Figure 88 with Outdoor sensor Optional for Combi with Outdoor sensor Theory of Outdoor Reset Control OTC/reset These scale ranges are related to the outdoor temperatures, and 4.

  • Page 67: Dhw Settings (Combi Only)

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 27 Controls and operation 28 DHW Settings (Combi Only) Adjustments for Heating Only Boilers Boiler must be set on comfort mode with Outdoor sensor DHW SETTINGS Figure 90 OTC CURVES (Figure 82, page 63).
  • Page 68 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 28 DHW Settings (Combi Only) (continued) Figure 95 Figure 96 Freestyle 155 - DHW PRODUCTION G.P.M. Freestyle 120 - DHW PRODUCTION G.P.M. 14.5 11.5 13.5 12.5 10.5 11.5 10.5 Freestyle 155 Freestyle 120 Delta T (ºF)

  • Page 69: Standard Altitude

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 29 Standard Altitude Standard Altitude Boiler Adjustment Figure 97 to enter the parameter setup menu. Standard Altitude parameter “b04”, “b05” and “b06”, are shown in Table. 2. Roll down the menu by pressing the CH button until the Model parameter “b04”...

  • Page 70: High Altitude

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 30 High Altitude HIGH ALTITUDE BOILER ADJUSTMENT enter the parameter setup menu. rameter “b04”, “b05” and “b06”, are shown in the Table below 2. Roll down the menu by pressing the CH button until the parameter “b04”...
  • Page 71 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 30 High Altitude Blower Speeds Figure 99 120KBTU - Natural Gas LOW FIRE HIGH FIRE (CH & DHW) ALTITUDE Blower Speed Blower Speed CO2 (%) CO (PPM) CO2 (%) CO (PPM) (b04 &...
  • Page 72 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 30 High Altitude Blower Speeds Figure 100 155KBTU - Natural Gas LOW FIRE HIGH FIRE (CH & DHW) ALTITUDE Blower Speed Blower Speed CO2 (%) CO (PPM) CO2 (%) CO (PPM) (b04 &...

  • Page 73: Startup - Quick Start Guide Using Default Settings

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual Startup — Quick Start Guide using default settings Figure 101 62-67 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 5-75 insure the following first before you proceed: All gas lines are connected and tested for leaks, and if the boiler is to operate on LP fuel, and the unit has been converted properly from Natural gas to Liquefied Petroleum (Propane) gas and set up as directed in the boiler...
  • Page 74 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 31 Startup — Quick Start Guide using default settings (continued) QUICK START GUIDE System start (continued) “Test Mode Operation” To operate the boiler in test mode, press the CH “-” and “+”...

  • Page 75: Startup

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 32 Startup CIRCULATOR EXERCISING and FREEZE PROTECTION since drinking water chloride levels are typically less than CIRCULATOR EXERCISING 5 ppm. The FreeStyle ® control will automatically start the circulator out- 2.
  • Page 76 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 32 Startup (continued) Freeze protection (if used) build up in the heat exchanger, reducing heat severe personal injury, death or substantial prop- erty damage: Purge air from water system 1.
  • Page 77 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 32 Startup (continued) Check inhibitor concentration X100 inhibitor is required annually 1. It is required that the boiler have Sentinel X100 inhibi- heat exchanger. Failure to comply may result in acceler- and 8.5.

  • Page 78: 6Wduwxs ² ¿Qdo Fkhfnv

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 33 6WDUWXS ² ¿ QDO FKHFNV Inspect/fi ll condensate system Check for gas leaks condensate trap. (See page 49 use a leak detector or smell near the fl oor and around 1.
  • Page 79 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 33 6WDUWXS ² ¿QDO FKHFNV (continued) Final checks before lighting the boiler 3. The boiler lights at the maximum heating 100% rate dis- played on the LCD display. ❏ 4.
  • Page 80 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 33 6WDUWXS ² ¿QDO FKHFNV (continued) FreeStyle Figure 105 Part number 550-142-950/0919...
  • Page 81 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 33 6WDUWXS ² ¿QDO FKHFNV (continued) ❏ page 10 outside the range given in Figure 107, page 82 FreeStyle 80, 120 or 155. or Figure 110, page 83 DO NOT attempt to mea- sure gas valve outlet pres- sure correct the problem, then shut down the boiler...
  • Page 82 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 33 6WDUWXS ² ¿QDO FKHFNV (continued) Using a combustion analyzer check the CO val- ues at low and high fire. It should be within values Setting the Air/Gas Ratio valve Figure 107 below 0.2% or above 1%.
  • Page 83 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 33 6WDUWXS ² ¿QDO FKHFNV (continued) Re-check the Maximum and Minimum At Minimum Rate: Rate to stabilize. Figure 109 Torx (T-40 male driver) until the CO the minimum rate output ensuring the CO setting level has Figure 110), confirm that the CO/CO remained unchanged and confirm that the CO/CO...

  • Page 84: KhfnRxwVwduwxs Yhul¿Fdwlrq

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 34 &KHFNRXWVWDUWXS YHUL¿FDWLRQ ❏ Adjust and test boiler controls adjusted to provide design temperature to system? ❏ systems? Have the following been done? ❏ ❏ ❏ ❏ Water chemistry verified per page 75? installed) —...

  • Page 85: Annual Startup And General Maintenance

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 35 Annual startup and general maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped property damage. Figure 111 FreeStyle ® Daily Monthly Every 6 months Part number 550-142-950/0919...

  • Page 86: Annual Startup

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 36 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.
  • Page 87 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 36 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 111, page 85 to ground terminal screw.
  • Page 88 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 36 Annual startup (continued) Check boiler relief valve remove burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to 3. To access the burner, remove the heat exchanger cover severe scald potential.

  • Page 89: Troubleshooting

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting ® FreeStyle the “ ” ( page 136 ). Record the boiler size and Con- Sheet to boiler. ® FreeStyle 2. Check the 3. See Figure 80, page 62 Hold reset button for 20 seconds: TS Flashing (parameter) Failure to adhere to these guide-...
  • Page 90 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) Check ignition sequence Figure 114 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 FLAME LOSS Heat demand detection time CH mode:...
  • Page 91 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) Check fl ame signal Figure 115 FreeStyle ® control display (see pages 62 to 66 Fuse located on rear of circuit board FreeStyle ® 80, 120 or 155. The fl ame signal value must be at least 255 on high fi...
  • Page 92 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) FreeStyle ® Control diagnosis Table 3 or 4 A” see Table 3 button (Item 6 - Figure 80, page 62 F”, see Table 4, page 95) cause temporary shutdowns that are automatically reset as soon Protection and error conditions 1.
  • Page 93 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 118 (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. Check the wiring of the electrode and that it is Ignition/detection electrode fault correctly positioned and free of any deposits...
  • Page 94 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 119 (continued) Fault Code Fault Condition Correction Probe damaged Exhaust probe fault Check the wiring or replace the exhaust Wiring shorted probe Wiring disconnected Sensor damaged Check the wiring or replace the sensor Delivery sensor 2 fault...
  • Page 95 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 120 (continued) Blocking codes there is also an “F Table 4 The Exhaust gases temperature is too high. The CH supply water temperature sensor 1 error. The CH return water temperature sensor error.
  • Page 96 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 121 (continued) Display Condition FAULT 07 = If the exhaust gases temperature becomes higher than Maximum exhaust gases temperature and the high tem- perature is present longer than 5 seconds, controller will stop indicating fault 7, where he will stay for 15 minute.
  • Page 97 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 122 (continued) Display Condition FAULT 34 = Low voltage (less than 100VAC) will trigger this error. This is only an indication, the heat request is not switched off. When voltage brought is back (over 100VAC), error is resolved.
  • Page 98 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 123 Configuration mode The display starts with showing “b01 parameters; between “b01” and “b28 it is possible to adjust his value (not flashing). The value is automatically saved. Parameter Description Default Note...
  • Page 99 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 124 Installer mode reset CH+ and CH- push buttons it is possible to select reset ”. blinking Transparent parameter mode See Figure 125 thru 128, pages 99-101. blinking Inquiry mode See Figure 129 &...
  • Page 100 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 126 Parameter Description Default Note DHW conf. dependent /HJLRQHOOD SURWHFWLRQ  '+: FRQ¿J  ZLWK VHQVRU /HJLRQHOOD SURWHFWLRQ  '+: FRQ¿J  ZLWK WKHUPRVWDW '+: RII PRGH  '+: FRQ¿J  DHW conf.
  • Page 101 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 127 reset reset “ FreeStyle Figure 128 “b01” “b02” “b04” “b05” “b06” “b10” “b12” “b22” “P01” “P02” “P04” Boiler S/W mode Boiler Var. Out Vent Ignition CH Slope...
  • Page 102 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 130 blinking Boiler water pressure switch status 2SHQ  &ORVHG blinking Actual PWM modulating Pump (%) 0LQ  0D[  blinking Actual Step of Triac mod. mode (Num) 0LQ  0D[  blinking $FWXDO )ODPH &XUUHQW X$  ...
  • Page 103 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 132 (continued) System Parameters list (default settings) number (See Parameter “b01 a communication package running on the PC. Some parameters are available by the installer in the “ts”, Transparent Parameter Table 5 FreeStyle ®...
  • Page 104 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 133 (continued) Category Unit Range Description Num. Address Description High Value '+: FRQ¿J  CL5 – 066E DHW P factor '+: FRQ¿J  10,2 CL5 –...
  • Page 105 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 134 (continued) Category Unit Range Description Num. Address Description High Value '+: FRQ¿J  CL5 – 066E DHW P factor '+: FRQ¿J  10,3 CL5 –...
  • Page 106 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 135 (continued) Category Unit Range Description Num. Address Description High Value Central Heating constant CH P factor Central Heating constant CH I factor Central Heating ML –...
  • Page 107 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 136 (continued) Category Unit Range Description Num. Address Description High Value Dom. Hot Water CL5 – 06F8 DHW maximum output Dom. Hot Water Free - TBD Dom.
  • Page 108 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 137 (continued) Category Unit Range Description Num. Address Description High Value History ML – 8061 Total num. of hours with power supply ON - LSB History ML –...
  • Page 109 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 138 (continued) Category Unit Range Description Num. Address Description High Value Flame current supervision ML – 80D5 Flame current on level1 offset Flame current supervision ML –...
  • Page 110 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 37 Troubleshooting (continued) ® FreeStyle Figure 139 (continued) Some informations can be accessed with a communication package running on the PC. Category Unit Description Num. Address Description Boiler CL4 – A532 CH supply sensor1 temperature °F *10 Boiler...

  • Page 111: Maintenance

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 38 Maintenance Clean condensate trap Disconnect power 1. See Figure 140 . 2. Disconnect top clean out cap nut that secures the trap body to the boiler condensate connection. nect all electrical power to the boiler 3.
  • Page 112 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 38 Maintenance (continued) Figure 142 Figure 144 2. Remove two (2) Phillips head screws securing the ignition electrode to the boiler heat exchanger. Use care when removing and handling igniter. necessary.
  • Page 113 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 38 Maintenance (continued) Figure 146 Figure 148 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 114 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 38 Maintenance (continued) Inspect and clean the heat exchanger Wait until heat exchanger/boiler is cooled down severe injury. 1. See Figures 149 and 153. Figure 151 2. Use a 10mm wrench or socket to remove the five (5) nuts that secure the burner cover plate to the heat exchanger.
  • Page 115 FreeStyle ® Series 2 wall mount gas-fired water boiler — Boiler Manual 38 Maintenance (continued) Procedure For Cleaning Of Internal Heat Figure 153 Heat exchanger components Exchanger Circuit This 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 water circuit.
  • Page 116 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 38 Maintenance (continued) Actions For Cleaning Of Heat Exchanger Do not carry out any operation on the sealed control parts. Water Circuit should be carried out in an appropriate manner, in accordance with current standards.
  • Page 117 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 38 Maintenance (continued) Actions for chemical cleaning of Hot Water Can Scald! Domestic hot water circuit less. automatic mixing valve When installing an , selection boiler inlet. recommendations and instructions. Release residual pressure in domestic hot water circuit in the boiler by opening a hot water tap downstream ing, dish washing and other sanitizing needs will scald and...
  • Page 118 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 38 Maintenance (continued) ombi 80/120 flat plate heat Figure 158 exchanger removal for cleaning screw placed next to the CH return (5), see Figure 156. placed next to heat exchanger return. Figure 156 ombi 155 flat plate heat exchanger removal for cleaning...
  • Page 119 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 38 Maintenance (continued) Combi 80/120 flat plate heat exchanger reinstalled Figure 160 The four (4) new gaskets must be placed in the DHW inlet and DHW return plate connections to seal brazed plate heat exchanger.

  • Page 120: Replacement Parts

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 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- WHEN OPERATING THE BOILER ON PROPANE GAS be covered by warranty and may damage boiler or impair operation.
  • Page 121 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) Figure 164 M&G Simpson-Duravent PolyPro SIDEWALL concentric vent/air kit (color: white) Antifreeze, Sentinel X500..592-900-029WT 2” polypropylene pipe ..2PPS-HK Corrosion inhibitor, Sentinel X100 .
  • Page 122 FreeStyle ® Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) FreeStyle Figure 165 ® Jacket parts — 80/120/155 (sheet metal for Combi and Heating Only boilers) Item Name Part Number Jacket door 640-000-067 Jacket left side 640-000-065 Jacket right side 640-000-066...
  • Page 123 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) ® FreeStyle Figure 166 Item Name Part Number Control module assembly 640-000-003WT Control module display cover 640-000-004 Pressure-temperature assembly 640-000-006 Wire harness assembly - Combi - 80/120 640-000-005 Wire harness assembly - Combi - 155 640-000-085...
  • Page 124 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) ® FreeStyle Figure 167 Combi Model Item Name Part Number FS-80 FS-120 640-000-116 Heat Exchanger 640-000-117 Flue Sensor Temperature 640-000-011 Blower Assembly 640-000-020WT Blower Gasket 640-000-021 Ignitor 640-000-109WT...
  • Page 125 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) ® FreeStyle Figure 168 Combi continued Part number 550-142-950/0919...
  • Page 126 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) ® FreeStyle Figure 169 Heating Only Model Item Name Part Number FS-80 FS-120 640-000-116 Heat Exchanger 640-000-117 Flue Sensor Temperature 640-000-011 Blower Assembly 640-000-020WT Blower Gasket 640-000-021 Ignitor 640-000-109WT...
  • Page 127 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) ® FreeStyle Figure 170 Heating Only continued Part number 550-142-950/0919...
  • Page 128 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) ® FreeStyle Figure 171 Combi 155 ( Item Name Part Number Heat Exchanger 640-000-118 Flue Sensor Temperature 640-000-011 Blower Assembly 640-000-081WT Blower Gasket 640-000-021 Ignitor 640-000-109WT Central Heat Exchanger Insulation 640-000-010...
  • Page 129 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) ® FreeStyle Figure 172 Combi 155 ( continued Part number 550-142-950/0919...
  • Page 130 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) ® FreeStyle Figure 173 Heating Only 155 ( Item Name Part Number Heat Exchanger 640-000-118 Flue Sensor Temperature 640-000-011 Blower Assembly 640-000-081WT Blower Gasket 640-000-021 Ignitor 640-000-109WT Central Heat Exchanger Insulation...
  • Page 131 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 39 Replacement parts (continued) ® FreeStyle Figure 174 Heating Only 155 ( continued Part number 550-142-950/0919...

  • Page 132: Connections, Dimensions And Engineering Data

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 40 Connections, Dimensions and Engineering Data ® FreeStyle Figure 175 Part number 550-142-950/0919...
  • Page 133 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 40 Connections, Dimensions and Engineering Data (continued) ® FreeStyle Figure 176 Part number 550-142-950/0919...
  • Page 134 FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 40 Connections, Dimensions and Engineering data (continued) ® FreeStyle Figure 177 Series 2 Boiler Model weight weight required FS-80 Combi 1.110 2” or 3” 15.0 1.306 2” or 3” 15.0 FS-120 Combi 1.331...

  • Page 135: Ratings

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 41 Ratings ® FreeStyle Figure 178 Series 2 * Low Lead Content (Note 7) AHRI Certified Ratings Boiler % Input derate vs vent length Vent/ Model Comb. Air (Values shown are at MAX vent/air pipe length — Heating Seasonal Water...

  • Page 136: Qvwdoodwlrq Dqg 6Huylfh &Huwl¿Fdwh

    FreeStyle Series 2 wall mount gas-fired water boiler — Boiler Manual 42 ,QVWDOODWLRQ DQG 6HUYLFH &HUWL¿FDWH Boiler Start-Up Data FreeStyle ® Boiler Model / Series ________ / Series ____ Date installed ________________ # +LJK ¿UH BBBBBB /RZ ¿UH BBBBBB Part Number ____________ FUEL: Natural ____ LP ____ Btu Input ___________________ &2 # +LJK ¿UH BBBB SSP /RZ ¿UH BBBB SSP...

This manual is also suitable for:

Freestyle 80Freestyle 120Freestyle 155

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