Page 1 FreeStyle ® Wall Mount Gas-Fired Condensing Boilers Combi & Heat Only Models Series 2 80/120/155 – Boiler Manual Low Lead Content • Installation • Maintenance • Startup • Parts 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 qualified heating installer/service technician.
Page 2: Table Of Contents
FreeStyle – ® series wall mount gas fired water boiler boiler manual Contents Page 21 Gas piping 1 Please read before proceeding 22 Field wiring 2 Prepare boiler location 23 Wiring diagram — FS-80/120 Combi Ladder 3 Prepare boiler 23 Wiring diagram — FS-80/120 Combi Schematic 4 Converting boiler to propane 24 Wiring diagram —...
Page 3: Please Read Before Proceeding
Thermal shock can cause heat exchanger Boiler water — to crack. y To avoid severe burns, allow boiler to y The FreeStyle heat exchanger is made of cool before performing maintenance. Freeze protection fluids — stainless steel, and requires that system...
Page 4: Prepare Boiler Location
Vent and air piping or substantial property damage. 5. The FreeStyle® boiler must be installed so that gas control The FreeStyle® boiler requires a special vent system, designed for pressurized venting. FreeStyle® boilers are rated ANSI Z21.13 system components are protected from dripping or spraying Direct Vent (pressurized vent, likely to condense in the vent).
Page 5 FreeStyle – ® series wall mount gas fired water boiler boiler manual 2 Prepare boiler location continued Clearances A Provide combustion air/ventilation openings per Fig- ure 23, page 20 or as otherwise directed in this manual or by Provide clearances from applicable codes.
Page 6: Prepare Boiler
You must pipe combustion air to the boiler air contamination problems. air intake See Table 1 for products and areas which may cause contaminated Install air inlet piping for the FreeStyle® boiler as combustion air. described in this manual. To prevent potential of severe personal injury or...
Page 7 FreeStyle – ® series wall mount gas fired water boiler boiler manual 3 Prepare boiler continued Wall-mounting requirements Install the wall-mount bracket DO NOT attempt to attach the wall mount bracket 1. Locate the studs — must be on 16-inch centers. See previous using anchors or any means other than directly instructions if studs are not on 16-inch centers.
Page 8 FreeStyle – ® series wall mount gas fired water boiler boiler manual 3 Prepare boiler continued Hydrostatic pressure test Fill and pressure test DO NOT install a relief valve with a pressure 1. See Figure 5, page 9, for use with the following instructions.
Page 9 FreeStyle – ® series wall mount gas fired water boiler boiler manual 3 Prepare boiler continued Figure 5 Figure 6 Install pipe fittings for relief valve and pressure/ Install piping components required for hydrostatic test ( temperature gauge — DO NOT mount relief...
Page 10: Converting Boiler To Propane
FreeStyle – ® series wall mount gas fired water boiler boiler manual 4 Converting boiler to propane Natural to LP Conversion Kit Part Numbers Prepare boiler for propane FreeStyle 80/120/155 required) ® FS-80 LP P/N 640-000-024WT NG to Propane Gas Conversion Kit contents: 36602430 Venturi - 10.6 GPL...
Page 11 1. Remove two (2) screws on the bottom flange of front panel, — FreeStyle® 80: 3.5” w.c.; out and lift up to remove the front panel. — FreeStyle® 120: 3.5” w.c.; 2. Remove the one (1) screw holding control module in place —...
Page 12 FreeStyle – ® series wall mount gas fired water boiler boiler manual 4 Converting boiler to propane continued 3. Loosen the bottom swivel nut of gas pipe and unscrew the top swivel nut “A” Figure 12, Item 3 from the gas valve venturi LEGEND for Figures 12, 13, 14, 15.
Page 13 FreeStyle – ® series 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 Gas pipe re-assembled to LP venturi fitting 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 wall mount gas fired water boiler boiler manual 5 Gas piping — sizing gas lines Boiler gas connection is ½” NPT for 80/120 boilers Figure 18 Pipe capacity for 0.60 specific gravity natural and ¾” NPT for 155 boilers. Size gas lines large gas;...
Page 15: Venting/Air Piping - General
The boiler cannot be common vented with any other ap- vents when tested as outlined herein, return doors, win- pliance . When an existing boiler is replaced with a FreeStyle® dows, exhaust fans, fireplace dampers, and any other boiler, the boiler CANNOT use the existing common vent. The gas-burning appliance to their previous conditions of use.
Page 16 FreeStyle – ® series wall mount gas fired water boiler boiler manual 6 Venting/air piping — general continued Figure 20 Venting and air piping — DIRECT VENT ONLY — OPTIONS and PIPING LIMITS 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 wall mount gas fired water boiler boiler manual 6 Venting/air piping — general continued Figure 21 Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet local codes (see Figure 164, page 121 for part/kit numbers)
Page 18: Commonwealth Of Massachusetts Installations
FreeStyle – ® series wall mount gas fired water boiler boiler manual 7 Commonwealth of Massachusetts installations Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts, the boiler must be installed by a licensed plumber or gas fitter. Read and comply with the instructions below.
Page 19: Vent Termination Requirements
FreeStyle – ® series 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
Gas Code, ANSI Z223.1/NFPA 54 - latest edition, or applicable provisions of the local building codes. The FreeStyle boiler CANNOT be in the same space with other appliances if clearances around the FreeStyle ® are ® less than the recommended service clearances shown in Figure 1, page 5.
Page 21: Direct Vent - Sidewall With Separate Pipes
The vent and air pipes must be secured with braces, and all clearances and lengths must be maintained. 3. The air inlet of a FreeStyle® boiler is part of a direct vent con- Space braces no further than 24 inches apart.
Page 22 FreeStyle – ® series wall mount gas fired water boiler boiler manual 10 DIRECT VENT — Sidewall with separate pipes continued Figure 25 Multiple separate pipes sidewall terminations — See notices on previous page. maintain vertical spacing between vent and air fittings shown in Figure 24, page 21.
Page 23: Direct Vent - Sidewall Concentric
Figure 28, page 24 for U. S. installations. USE SWEEP ELBOWS FOR ALL VENT AND AIR 3. The air inlet of a FreeStyle® boiler is part of a direct PIPING — DO NOT use short radius elbows for vent or air piping.
Page 24 FreeStyle – ® series wall mount gas fired water boiler boiler manual 11 DIRECT VENT — Sidewall concentric (continued) Figure 28 Termination location — concentric See notices on previous page. termination — multiple boilers — clearance from vent of one to air intake of Install termination —...
Page 25: Direct Vent - Vertical With Separate Pipes
Step 9 Maintain clearances shown above. Vent and air terminations must be fitted with a bird screen as shown. 3. The air inlet of a FreeStyle® boiler is part of a direct vent connection. It is not classified as a forced air USE SWEEP ELBOWS FOR ALL VENT AND AIR PIPING —...
Page 26 FreeStyle – ® series wall mount gas fired water boiler boiler manual 12 DIRECT VENT — Vertical with separate pipes (continued) Figure 31 Terminations for multiple boilers See notices on previous page. Prepare roof penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
Page 27: Direct Vent - Vertical Concentric
U. S. installations (see Figure 33, page 28). 3. The air inlet of a FreeStyle® boiler is part of a direct USE SWEEP ELBOWS FOR ALL VENT AND vent connection. It is not classified as a forced air in- AIR PIPING —...
Page 28 FreeStyle – ® series wall mount gas fired water boiler boiler manual 13 DIRECT VENT — Vertical concentric (continued) Figure 33 Vertical termination — 3” PVC concentric — See notices on previous page. single or multiple boilers Prepare roof penetrations 1.
Page 29: Direct Vent - Vertical Vent /Sidewall Air
FreeStyle – ® series wall mount gas fired water boiler boiler manual 14 DIRECT VENT — Vertical vent /sidewall air Allowable vent/air pipe materials & lengths Figure 35 INSTALLATION SEQUENCE — Vertical vent/ sidewall air Use only the vent materials and kits listed in Fig- ure 21, page 17.
Page 30 FreeStyle – ® series wall mount gas fired water boiler boiler manual 14 DIRECT VENT — Vertical vent /sidewall air (continued) Determine location for air inlet elbow Figure 36 Vent termination (through the roof) for direct vent: vertical vent / sidewall air 1.
Page 31: Concentric Termination, Typical (Sidewall Or Vertical)
FreeStyle – ® series wall mount gas fired water boiler boiler manual 15 Concentric termination, typical (sidewall or vertical) Figure 38 PVC concentric termination assembly — DO NOT LEGEND for Figure 38 attach the rain cap until the termination has been 1 —...
Page 32: Vent And Air Piping And Boiler Connections
FreeStyle – ® series wall mount gas fired water boiler boiler manual 16 Vent and air piping and boiler connections Follow termination instructions Figure 40 Flue and vent adapter and gasket 1. Read and follow all instructions for the termination type used before proceeding with this page.
Page 33 FreeStyle – ® series wall mount gas fired water boiler boiler manual 16 Vent and air piping and boiler connections (continued) Figure 43 Vent (flue) and air adapters in place — Use adapters if using 2-inch pipe. ADAPTERS 1. Clean and deburr inside and outside of both ends of air and vent pipes.
Page 34 FreeStyle – ® series wall mount gas fired water boiler boiler manual 16 Vent and air piping and boiler connections (continued) Control selection for vent material For example: CPVC, Polypropylene, or AL29-4C stainless steel. Perform at start-up final checks “b22” parameter PVC solid core, ........
Page 35: Install Water Piping
FreeStyle – ® series wall mount gas fired water boiler boiler manual 17 Install water piping Domestic Water Piping – Combi Boiler should be capable of at least the Maximum input of the boiler Maximum pressure Not exceeding 130 PSIG. The pressure relief valve’s discharge should be per instructions in the Warning box,...
Page 36 FreeStyle – ® series wall mount gas fired water boiler boiler manual 17 Install water piping (continued) General piping information Carbonate must be treated with a “Water Softener” prior to entering the boiler. Plugging of the domestic system by Additional controls, if required scaling or accumulation of dirt is not the responsibility of Weil-McLain, and suitable steps must be taken to avoid it.
Page 37: Recirculation (If Used)
FreeStyle – ® series wall mount gas fired water boiler boiler manual 17 Install water piping (continued) 2. The circulator cannot run continuously as bypass through Figure 47 Suggested pipe sizing for system headers the mixing valve will eventually allow the temperature on and zone piping —...
Page 38 FreeStyle – ® series wall mount gas fired water boiler boiler manual 17 Install water piping (continued) Figure 48 Recirculation piping diagram (if used) Part number 550-142-950/0122...
Page 39: Primary/Secondary System Piping
FreeStyle – ® series wall mount gas fired water boiler boiler manual 18 Primary/Secondary System Piping Expansion Tank Location System water piping methods Primary/secondary piping to boiler Figure 51, page 40show typical installation of the system expansion tank. It is highly recommended that you locate the air separator...
Page 40 FreeStyle – ® series wall mount gas fired water boiler boiler manual 18 Primary/Secondary System Piping (continued) Figure 51 Piping to diaphragm (or bladder) expansion tank Figure 52 FreeStyle Pressure drop through ® 80/120/155 heat exchanger (graphs and table) (GPM) Total Loss - Ft.
Page 41: Closed-Type Expansion Tank
FreeStyle – ® series wall mount gas fired water boiler boiler manual 18 Primary/Secondary System Piping (continued) Closed-type expansion tank: Figure 53 Piping to closed-type expansion tank DO NOT use a closed-type tank if connecting to a water heater that is equipped with an automatic air vent.
Page 42: Install Relief Valve
FreeStyle – ® series wall mount gas fired water boiler boiler manual 18 Primary/Secondary System Piping (continued) Install relief valve 1. Install relief valve in 1” x 1” x ¾” (for FS-80/120) or 1 ” x 1 ” x ¾”...
Page 43: Zone Valve Zoning - Primary/Secondary
Connect system circulator to HEAT Circ. Controlling the Zones output. 1. The FreeStyle® control can be used to control space heating Use isolation relays if connecting 3-wire zone only, domestic water heating only, or both. Refer to field wiring, valve end switches to the HEAT input.
Page 44: Circulator Zoning - Primary/Secondary
NOTE: (Applies to Figures 54, 55 & 56) 1. The FreeStyle® control can be used to control space heating only, domestic water heating only, or both. Refer to field wiring, begin- Add boiler and tank head loss for pump sizing.
Page 45: Circulator Zoning - Multiple Temperature Zones With
TIME setting can be adjusted to limit how long this oc- curs. Set the MAX ON TIME to “0” to disable domestic 1. The FreeStyle® control can be used to control space heating only, priority. See page 67 for setting instructions.
Page 46: Multiple Boiler Installations
FreeStyle – ® series wall mount gas fired water boiler boiler manual 19 Multiple boiler installations FreeStyle ® Figure 57 Side-to-side mounting of multiple boilers Placing multiple boilers 1. Locate multiple boilers with spacings shown in Figure 57. 2. Provide indicated clearances around boilers for access and ser- vicing.
Page 47 FreeStyle – ® series wall mount gas fired water boiler boiler manual 19 Multiple boiler installations (continued) FreeStyle ® Figure 58 Piping schematic — typical piping for multiple Heating Only boilers Legend for Figure 58 1 Flow/check valve 10 Cold water supply 11 Supply water temperature control (when used).
Page 48 FreeStyle – ® series wall mount gas fired water boiler boiler manual 19 Multiple boiler installations (continued) DHW tank piping with multiple When using a multiple-boiler control with lead boiler rotation, it is recommended that the boiler connected to FreeStyle boilers ®...
Page 49: Install Condensate Line
FreeStyle – ® series wall mount gas fired water boiler boiler manual 20 Install condensate line Figure 62 Prepare condensate trap assembly Filling the condensate trap assembly This boiler is equipped with an internal air-trap to drain off condensate. 1. Remove the condensate trap kit from the accessories bag.
Page 50: Gas Piping
FreeStyle – ® series wall mount gas fired water boiler boiler manual 21 Gas piping Figure 63 Connect gas supply piping ® boilers are shipped ready to fire FreeStyle (Heating Only boiler shown). natural gas ONLY. You must install the pro- pane venturi if the boiler will be connected to propane.
Page 51 Check the operational (working) gas inlet boiler startup, while boiler is at high fire) pressure — FreeStyle® 80: 3.5” w.c.; — FreeStyle® 120: 3.5” w.c.; 1. Set up the boiler to operate at maximum rate as described in — FreeStyle® 155: 3.5” w.c.
Page 52: Field Wiring
FreeStyle – ® series wall mount gas fired water boiler boiler manual 22 Field wiring E L E C T R I C A L S H O C K The installation must comply Wi r i n g mu s t b e N . E . C .
Page 53 • Outdoor sensor uses the back connection block, see Fig- ure 66, page 52, Item 138, (right side of block … terminals 5 and The control of the Heating Only model of the FreeStyle 6 ) for the Heating Only boiler. boiler is capable of managing two (2) separate circulators, •...
Page 54: Wiring Diagram - Fs-80/120 Combi Ladder
FreeStyle – ® series wall mount gas fired water boiler boiler manual 23 Wiring diagram — FS-80/120 Combi Ladder FreeStyle ® Figure 72 80/120 Combi Ladder Wiring Diagram 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 Combi Schematic
FreeStyle – ® series wall mount gas fired water boiler boiler manual 23 Wiring diagram — FS-80/120 Combi Schematic FreeStyle ® Figure 73 80/120 Combi Schematic Wiring Diagram Part number 550-142-950/0122...
Page 56: Wiring Diagram - Fs-80/120 Heating Only Ladder
FreeStyle – ® series wall mount gas fired water boiler boiler manual 24 Wiring diagram — FS-80/120 Heating Only Ladder Figure 74 FreeStyle ® 80/120 Heating Only Ladder Wiring Diagram 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 wall mount gas fired water boiler boiler manual 24 Wiring diagram — FS-80/120 Heating Only Schematic ® Figure 75 FreeStyle 80/120 Heating Only Schematic Wiring Diagram Part number 550-142-950/0122...
Page 58: Wiring Diagram - Fs-155 Combi Ladder
FreeStyle – ® series wall mount gas fired water boiler boiler manual 25 Wiring diagram — FS-155 Combi Ladder FreeStyle ® Figure 76 155 Combi Ladder Wiring Diagram NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local requirements.
Page 59: Wiring Diagram - Fs-155 Combi Schematic
FreeStyle – ® series wall mount gas fired water boiler boiler manual 25 Wiring diagram — FS-155 Combi Schematic FreeStyle ® Figure 77 155 Combi Schematic Wiring Diagram Part number 550-142-950/0122...
Page 60: Wiring Diagram - Fs-155 Heating Only Ladder
FreeStyle – ® series wall mount gas fired water boiler boiler manual 26 Wiring diagram — FS-155 Heating Only Ladder FreeStyle ® Figure 78 155 Ladder Wiring Diagram NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local requirements.
Page 61: Wiring Diagram - Fs- 155 Heating Only Schematic
FreeStyle – ® series wall mount gas fired water boiler boiler manual 26 Wiring diagram — FS- 155 Heating Only Schematic FreeStyle ® Figure 79 155 Heating Only Schematic Wiring Diagram Part number 550-142-950/0122...
Page 62: Controls And Operation
FreeStyle – ® series wall mount gas fired water boiler boiler manual 27 Controls and operation Control Introduction ® FreeStyle boiler is a high-efficiency condensing pre-mix ap- Thanks to the microprocessor control and adjustment system pliance for central heating and hot water production, running...
Page 63 FreeStyle – ® series wall mount gas fired water boiler boiler manual 27 Controls and operation (continued) Central heating operation The Central Heating heat demand (generated by the Room Thermostat) is indicated by the flashing of the Hot Air symbol over the radiator (Items 12 and 13 - Figure 80, page 62).
Page 64 FreeStyle – ® series wall mount gas fired water boiler boiler manual 27 Controls and operation (continued) Initial power up mode Ensure the power is on to the boiler Figure 84 Initial power up mode Air purge Software version During the first 5 seconds, the display shows the software version of the control module.
Page 65 FreeStyle – ® series wall mount gas fired water boiler boiler manual 27 Controls and operation (continued) Adjustments Figure 86 Heating temperature settings 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).
Page 66 FreeStyle – ® series wall mount gas fired water boiler boiler manual 27 Controls and operation (continued) Adjustments for - Heating Only Boilers Figure 88 OTC settings with Outdoor sensor Optional for Combi with Outdoor sensor Theory of Outdoor Reset Control...
Page 67: Dhw Settings (Combi Only)
ΔT =50ºF] ΔT =70ºF] ΔT =90ºF] FS-80 FS-120 FS-155 Starting temperature Figure 94 DHW curve - FreeStyle 80 Figure 92 Compensation parallel offset curves, Typical copper fin tube /cast iron baseboard radiation. Freestyle 80 - DHW PRODUCTION G.P.M. Freestyle 80 Delta T (ºF)
Page 68 28 DHW Settings (Combi Only) (continued) Figure 95 DHW curve - FreeStyle 120 Figure 96 DHW curve - FreeStyle 155 Freestyle 155 - DHW PRODUCTION G.P.M. Freestyle 120 - DHW PRODUCTION G.P.M. 14.5 11.5 13.5 12.5...
Page 69: Standard Altitude
FreeStyle – ® series wall mount gas fired water boiler boiler manual 29 Standard Altitude Standard Altitude Boiler Adjustment Figure 97 STANDARD Altitude Fan Speeds for below 2,000’ installations (below 2,000’ installations) 1. Press DHW- and DHW+ buttons together for 10 seconds to enter the parameter setup menu.
Page 70: High Altitude
FreeStyle – ® series wall mount gas fired water boiler boiler manual 30 High Altitude HIGH ALTITUDE BOILER ADJUSTMENT (above 2,000’ installations) The Ignition speeds are the same for Standard and 1. Press DHW- and DHW+ buttons together for 10 seconds to enter the parameter setup menu.
Page 71 FreeStyle – ® series wall mount gas fired water boiler boiler manual 30 High Altitude Blower Speeds Figure 99 HIGH Altitude Fan Speeds for FS-120 boilers 120KBTU - Natural Gas LOW FIRE HIGH FIRE (CH & DHW) ALTITUDE Blower Speed...
Page 72 FreeStyle – ® series wall mount gas fired water boiler boiler manual 30 High Altitude Blower Speeds Figure 100 HIGH Altitude Fan Speeds for FS-155 boilers 155KBTU - Natural Gas LOW FIRE HIGH FIRE (CH & DHW) ALTITUDE Blower Speed...
Page 73: Startup - Quick Start Guide Using Default Settings
FreeStyle – ® series wall mount gas fired water boiler boiler manual Startup — Quick Start Guide using default settings Figure 101 Quick Start Guide - Default control settings, see instructions and figures on pages 62-67). QUICK START GUIDE FreeStyle After you have completed the installation of the ®...
Page 74 FreeStyle – ® series 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 start, create a demand for heat, open up a hot water faucet or turn up the thermostat.
Page 75: Startup
CIRCULATOR EXERCISING 5 ppm. The FreeStyle ® control will automatically start the circulator out- 2. Do not use the boiler to directly heat swimming pool or put and run for 10 seconds for each 72-hour period of inactivity.
Page 76 FreeStyle – ® series wall mount gas fired water boiler boiler manual 32 Startup (continued) Eliminate all system leaks. Continual fresh Freeze protection (if used) make-up water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat...
Page 77 FreeStyle – ® series 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- 1. Test the pH of a sample of system water at least annu- tor added to the system to prevent damage to the boilers’...
Page 78: Startup - Final Checks
FreeStyle – ® series wall mount gas fired water boiler boiler manual 33 Startup — final checks Inspect/fill condensate system Check for gas leaks Inspect/check condensate lines and fittings 1. Inspect the condensate drain line, condensate PVC fittings and Before starting the boiler, and during initial operation, condensate trap.
Page 79 ® ‰ plugged in? control. 2. Are external limit controls (if used) open? Is boiler water Verify that the boiler model is set correctly in the FreeStyle ‰ ® temperature above 200°F? control, and that it displays correctly. 3. Are thermostats set below room temperature? To start the boiler 4.
Page 80 FreeStyle – ® series wall mount gas fired water boiler boiler manual 33 Startup — final checks (continued) FreeStyle Figure 105 Operating instructions (WARNING — Verify that the ® control is set for the correct boiler model before proceeding.) Part number 550-142-950/0122...
Page 81 ‰ Check flame & combustion with instruments rating label. 11. Use the FreeStyle® control display to navigate to Manual 1. Enter into the “TEST” Mode to check combustion on High Test mode (see Figure 104, page 79) and force the firing rate Fire and Low Fire.
Page 82 FreeStyle – ® series wall mount gas fired water boiler boiler manual 33 Startup — final checks (continued) Using a combustion analyzer check the CO values at low and high fire. It should be within Setting the Air/Gas Ratio valve values from the table in Figure 107.
Page 83 FreeStyle – ® series wall mount gas fired water boiler boiler manual 33 Startup — final checks (continued) Re-check the Maximum and Minimum At Minimum Rate: Rate 1. Adjust the boiler to minimum output and allow the boiler to stabilize.
Page 84: Check-Out/Startup Verification
‰ gas ONLY. To fire on propane, you must follow the instructions in this manual to install the propane venturi. See page 10 for FreeStyle® 80, 120 or 155. Room thermostats set to desired room temperature (and ‰ Failure to comply could result in severe personal DHW aquastat, if installed, to desired DHW storage tem- injury, death or substantial property damage.
Page 85: Annual Startup And General Maintenance
FreeStyle – ® series 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 with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.
Page 86: Annual Startup
COVER PLATE INSULATION a. The integrity of the flue system and the flue seals; The FreeStyle® heat exchanger refractory b. The integrity of the boiler combustion circuit and the relevant seals; contain ceramic fiber materials that have c.
Page 87 FreeStyle – ® series wall mount gas fired water boiler boiler manual 36 Annual startup (continued) Check ignition wiring The boiler should be inspected and started 1. Check ignition cable electrical resistance. A good cable will annually, at the beginning of the heating have resistance between 950 and 1050 ohms.
Page 88 FreeStyle – ® series wall mount gas fired water boiler boiler manual 36 Annual startup (continued) 2. If flame is unsatisfactory at either high fire or low fire, Check boiler relief valve check combustion values. If combustion is properly ad- justed, turn off boiler and allow boiler to cool down.
Page 89: Troubleshooting
FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING VERIFY PROPER OPERATION AFTER SERVICING BEFORE TROUBLESHOOTING — BEFORE TROUBLESHOOTING — Before calling for troubleshooting assistance, fill in FreeStyle ® the “...
Page 90 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) Check ignition sequence The ignition sequence time line and operational description for the Combi and Heating Only boiler below help to understand the timing of the cycles. In your troubleshooting, refer to the numbers 1 through 7 as they describe each step of the ignition cycle.
Page 91 2. The flame signal value must be at least 25 on low fire for a FreeStyle ® 80, 120 or 155. The flame signal value must be at least 255 on high fire FreeStyle ® 80, 120 or 155. , reading at times 10 equals microamps of flame signal. If the flame signal drops below this level, the FreeStyle ®...
Page 92 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a com- plete diagnosis. FreeStyle Control diagnosis ® 1. The boiler control is equipped with an advanced self-diagnosis system. In case of a boiler fault, the display will flash together with the fault symbol (see Table 3 or 4) indicating the fault code.
Page 93 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) ® Figure 118 FreeStyle boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) Fault Code Fault Condition Correction Check the regular gas flow to the boiler and that...
Page 94 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 119 boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) Fault Code Fault Condition Correction Probe damaged Exhaust probe fault Check the wiring or replace the exhaust...
Page 95 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) ® Figure 120 FreeStyle boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) Blocking codes The boiler controller recognizes also the fault situations that can block the heat demands but do not lead to lockout condition.
Page 96 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 121 boilers — Fault displays and diagnostics Troubleshooting suggestions for (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 wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 122 boilers — Fault displays and diagnostics Troubleshooting suggestions for (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.
Page 98 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 123 Configuration mode for boilers — Parameters, Descriptions, Default displays and Notes Configuration mode By pressing the DHW- and DHW+ push buttons together for 10 seconds, it is possible to enter into the Configuration mode.
Page 99 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 124 Installer mode for boilers Installer mode reset By pressing the “ ” push button for 20 seconds, it is possible to entered the Installer mode. During this time, the OTC mode must not be entered.
Page 100 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) ® Figure 126 FreeStyle “tS” - Transparent Parameter mode for boilers (continued) Parameter Description Default Note DHW conf. dependent Legionella protection - DHW config. 2 with sensor Legionella protection - DHW config.
Page 101 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) ® Figure 127 FreeStyle “tS” - Transparent Parameter mode for boilers (continued) reset By pressing the “ ” push button for 1 second, it is possible to escape from the “Transparent parameter” mode. By pressing the reset “...
Page 102 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 130 “In” - Inquiry mode for boilers (continued) blinking Boiler water pressure switch status Open = 00, Closed = 20 blinking Actual PWM modulating Pump (%)
Page 103 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 132 boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) System Parameters list (default settings) There are 4 basic configurations within the DHW mode, selected by parameter DHW configuration (see Parameters list, Num. 1).
Page 104 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) ® Figure 133 FreeStyle boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) Category E2 prom parameters Unit Range Description Num. Address Description High Value DHW config.
Page 105 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) ® Figure 134 FreeStyle boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) Category E2 prom parameters Unit Range Description Num. Address Description High Value DHW config.
Page 106 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 135 boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) Category E2 prom parameters Unit Range Description Address Description High Value...
Page 107 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 136 boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) Category E2 prom parameters Unit Range Description Num. Address Description High Value Dom.
Page 108 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 137 boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) Category E2 prom parameters Unit Range Description Num. Address Description High...
Page 109 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 138 boilers — Fault displays and diagnostics Troubleshooting suggestions for (continued) Category E2 prom parameters Unit Range Description Num. Address Description High...
Page 110 FreeStyle – ® series wall mount gas fired water boiler boiler manual 37 Troubleshooting (continued) FreeStyle ® Figure 139 Troubleshooting suggestions for boilers — Fault displays and diagnostics (continued) Some informations can be accessed with a communication package running on the PC.
Page 111: Maintenance
FreeStyle – ® series 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 Electrical shock hazard — Discon- the boiler condensate connection.
Page 112 FreeStyle – ® series wall mount gas fired water boiler boiler manual 38 Maintenance (continued) Figure 142 Figure 144 Removal of Ignition electrode Boiler front panel removed (Combi 80/120 shown) 2. Remove two (2) Phillips head screws securing the ignition electrode to the boiler heat exchanger.
Page 113 FreeStyle – ® series wall mount gas fired water boiler boiler manual 38 Maintenance (continued) Figure 146 Figure 148 Inspection and removal of burner and gasket Inspecting exterior and cleaning the burner Remove the burner and burner gasket from the heat 7.
Page 114 FreeStyle – ® series wall mount gas fired water boiler boiler manual 38 Maintenance (continued) Inspect and clean the heat exchanger 8. Lightly spray clean water on all of the boiler coils and Wait until heat exchanger/boiler is cooled down before proceeding.
Page 115 FreeStyle – ® series 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 restora- tion of the functionality of the boiler as a result of operation with...
Page 116 FreeStyle – ® series wall mount gas fired water boiler boiler manual 38 Maintenance (continued) Actions For Cleaning Of Heat Exchanger regulations and according to the manufacturer’s instructions. Water Circuit Do not carry out any operation on the sealed control parts.
Page 117 FreeStyle – ® series wall mount gas fired water boiler boiler manual 38 Maintenance (continued) Actions for chemical cleaning of Hot Water Can Scald! Domestic hot water circuit y Consumer Product Safety Commission and some states recommend domestic hot water temperature of 130°F or Disconnect the unit from the electrical power supply less.
Page 118 FreeStyle – ® series wall mount gas fired water boiler boiler manual 38 Maintenance (continued) ombi 80/120 flat plate heat Figure 158 Removal of flat plate heat exchanger exchanger removal for cleaning (screw on right side) (Combi Only 80/120 shown) 5.
Page 119 FreeStyle – ® series wall mount gas fired water boiler boiler manual 38 Maintenance (continued) Combi 80/120 flat plate heat exchanger reinstalled Figure 160 Removal of flat plate heat exchanger by The four (4) new gaskets must be placed in the loosening the four fittings.
Page 120: Replacement Parts
FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts REPLACEMENT PART Failure to adhere to these guidelines can NUMBERS result in severe personal injury, death or substantial property damage. Williamson-Thermoflo part numbers are found in this manual and in Williamson-...
Page 121 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) Figure 164 Miscellaneous parts and kits Part Number Part Number Description Description M&G Simpson-Duravent PolyPro SIDEWALL concentric vent/air kit (color: white) Antifreeze, Sentinel X500..
Page 122 FreeStyle – ® series 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...
Page 123 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) FreeStyle ® Figure 166 Control and electrical assemblies — 80/120/155 Part Number Item Name Control module assembly 640-000-003WT Control module display cover 640-000-004 Pressure-temperature assembly...
Page 124 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) FreeStyle ® Figure 167 Combi Boiler replacement kits and parts 80/120 ( Model Part Number Item Name FS-80 FS-120 640-000-116 — Heat Exchanger 640-000-117 —...
Page 125 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) FreeStyle ® Figure 168 Combi Boiler replacement kits and parts 80/120 ( ) continued Part number 550-142-950/0122...
Page 126 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) FreeStyle ® Figure 169 Heating Only Boiler replacement kits and parts 80/120 ( Model Part Number Item Name FS-80 FS-120 640-000-116 — Heat Exchanger 640-000-117 —...
Page 127 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) FreeStyle ® Figure 170 Heating Only Boiler replacement kits and parts 80/120 ( ) continued Part number 550-142-950/0122...
Page 128 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) FreeStyle ® Figure 171 Combi Boiler replacement kits and parts 155 ( Part Number Item Name Heat Exchanger 640-000-118 Flue Sensor Temperature 640-000-011 Blower Assembly...
Page 129 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) FreeStyle ® Figure 172 Combi Boiler replacement kits and parts 155 ( ) continued Part number 550-142-950/0122...
Page 130 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) FreeStyle ® Figure 173 Heating Only Boiler replacement kits and parts 155 ( Part Number Item Name Heat Exchanger 640-000-118 Flue Sensor Temperature 640-000-011...
Page 131 FreeStyle – ® series wall mount gas fired water boiler boiler manual 39 Replacement parts (continued) FreeStyle ® Figure 174 Heating Only Boiler replacement kits and parts 155 ( ) continued Part number 550-142-950/0122...
Page 132: Connections, Dimensions And Engineering Data
FreeStyle – ® series wall mount gas fired water boiler boiler manual 40 Connections, Dimensions and Engineering Data FreeStyle ® Figure 175 Dimensions and connections data — 80/120 (all dimensions in inches) Part number 550-142-950/0122...
Page 133 FreeStyle – ® series wall mount gas fired water boiler boiler manual 40 Connections, Dimensions and Engineering Data (continued) FreeStyle ® Figure 176 Dimensions and connections data — 155 (all dimensions in inches) Part number 550-142-950/0122...
Page 134 All of the boilers will automatically de-rate as vent/air pipe length increases, due to the pressure loss through the piping. See Figure 178, page 135 for details. All FreeStyle® installations require a separate vent pipe and termination for each boiler. Vent piping cannot be manifolded. Install and terminate vents as described in vent/air installation instructions in this manual.
Page 135: Ratings
Ratings are based on a tions only. For altitudes from sea level FreeStyle® boilers meet the Energy Star piping and pickup allowance of 1.15. An to 4,500 feet above sea level, please refer guidelines for energy efficiency.
Page 136: Installation And Service Certificate
FreeStyle – ® series wall mount gas fired water boiler boiler manual 42 Installation and Service Certificate Boiler Start-Up Data FreeStyle Date installed ________________ @: High fire ______% Low fire ______% Boiler Model / Series ® ________ / Series ____...

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