Page 1 FreeStyle Wall Mount Gas-Fired Central Heating Water Boilers 80/120 Boiler Manual Low Lead Content Quick Start Guide Pages 3 & 4 Available in the 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 OUNT GAS FIRED WATER BOILER Boiler Manual Contents Page 21 Field wiring..... . . 50 1 Quick Start Guide — using default settings ..3 22 Wiring diagram —...
Page 3: Quick Start Guide - Using Default Settings
56-61 QUICK START GUIDE After you have completed the installation of the FreeStyle Boiler (Combi or Central Heating only models) by the instructions provided in the manual, 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 con- verted properly from Natural gas to Liqueﬁed Petroleum (Propane) gas and set up as directed in the boiler manual.
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 “+” (See below and Figure 92, page 66) to activate the TEST mode.
Page 5 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 3OHDVH UHDG WKLV ÀUVW Failure to adhere to the guidelines below can result in severe personal injury, death or sub- stantial property damage. boiler. — Read all instructions, including in the order given.
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. 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 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 3 Prepare boiler continued Hydrostatic pressure test Fill and pressure test 1. See Figure 6, page 11, 2. CLOSE the boiler drain valve (item 10). Connect a hose to (item 8 and 9) to catch water drippings.
Page 11 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 3 Prepare boiler continued Figure 6 Figure 7 see legend below) (see legend below) 1 Boiler supply (outlet) connection, (male, ¾” NPT ) 2 Boiler return (inlet) connection, (male, ¾” NPT ) 3 Boiler relief valve, shipped loose with boiler —...
Page 12: Converting Boiler To Propane
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 4 Converting boiler to propane Figure 8 Prepare boiler for propane FreeStyle ™ 80/120 required) Boiler Propane operation model FreeStyle boilers must be 640-000-022WT Converting an existing natural gas- 640-000-024WT — For a boiler...
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 c. Nominal gas pressure: 11.0” w.c.
Page 14 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 4 Converting boiler to propane continued Figures 12, 13, 14 and 15 top swivel nut “A” Figure 13, Figure 13, Item 6. Control panel (page 13) Phillips head screws “O” Ring...
Page 15 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 4 Converting boiler to propane continued 5. Reassemble gas pipe and new washer to the venturi ﬁtting, 14. Restore electrical power, turn on gas by opening manual gas re-connect nut “A” and gas pipe “Item 3” to venturi and Perform Boiler Manual start-up Inspect the gas pipe ﬁtting connections on the gas...
Page 16: Gas Piping - Sizing Gas Lines
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 5 Gas piping — sizing gas lines Boiler gas connection is ½” NPT. Size gas lines large Figure 18 enough to provide gas to all connected appliances. Natural Gas: total accordance with Figure 18 and Figure 19.
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 boiler CANNOT use the existing common vent. The FreeStyle boiler requires its own vent and air piping, as speciﬁed in this manual.
Page 18 — FreeStyle OUNT 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 19 AL29-4C stainless pipe manu- by the manufacturer. facturer at the 3” PVC boiler vent connection and at the termination (if using FreeStyle ™ plate or concentric PVC Every joint on polypropylene vent piping must include termination).
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 550-142-850/0115...
Page 22: Boiler Room Air Openings
FreeStyle 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 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 19 speciﬁed.
Page 26: Direct Vent
— 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. 1. Air pipe penetration: 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 Figure 37 Follow termination instructions Vent adapter in Figure 21, page 19. Installing vent and air piping Flue adapter For polypropylene applications, comply with any additional requirements in the vent system manu- (Do Not use 3”...
Page 33 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 15 Vent and air piping and boiler connections (continued) 8. Insert the vent PVC pipe adapters (provided with boiler), 9. Connections must be 3” PVC or CPVC only — use tran- 2-inch pipe.
Page 34 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 15 Vent and air piping and boiler connections (continued) Figure 42 Control selection for vent material To insure proper boiler operation (Combi and Heating Only venting material. You MUST any other venting material that you installed other than PVC.
Page 35: Install Water Piping
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 16 Install water piping Domestic Water Piping – Combi Boiler Figure 44 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 47, page 38 expansion tank. It is highly recommended that you locate 1. Connect boiler to system only as shown in Figure 47, page 38.
Page 38 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 17 Primary/Secondary System Piping (continued) Figure 47 Figure 48 FreeStyle Total Loss - Ft Piping Est Head Loss - Ft Recommended BOILER Boiler (Boiler + Near Boiler (GPM) @ Boiler (Typical 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: ing to a water heater that is equipped with an automatic air vent. Figure 49, 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 boiler supply (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
Connect zone valve end switches to HEAT input. Controlling the Zones Connect system circulator to HEAT Circ. output. 1. The FreeStyle™ control can be used to control space heating only, domestic valve end switches to the HEAT input. beginning on page 51 Figure 50 ™...
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 (Applies to Figures 50, 51 & 52) beginning on page 51 Add boiler and tank head loss for pump 2.
Page 43: Circulator Zoning - Multiple Temperature Zones With Primary/Secondary
Controlling the Zones use the DHW input or DHW Circulator output on the FreeStyle™ control. 1. The FreeStyle™ control can be used to control space heating only, domestic water heating only, or both. connecting space heating zones to inputs 2. The boiler and circulators can also be operated by a zone controller and in some installations may be needed.
Page 44: Multiple Boiler Installations
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 18 Multiple boiler installations FreeStyle Figure 53 Placing multiple boilers 1. Locate multiple boilers with spacings shown in Figure 53. local codes. ensure accessibility. 4. Unpack, assemble and mount boilers according to instructions in this manual.
Page 45 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 18 Multiple boiler installations (continued) FreeStyle Figure 54 Legend for Figure 54 1 Flow/check valve 10 Cold water supply 11 Supply water temperature control (when used) 2 Isolation valves (when used)
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 the DHW tank is always set as the last boiler to operate in the sequence so that space heat can be maintained DHW direct connection—single tank...
Page 47: Install Condensate Line
Use materials approved by the authority having Figure 57 D1785, F441 or D2665. Cement and primer should have an overﬂow switch to prevent property FreeStyle™ 80, FreeStyle™ 120. 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 ﬁre) section “ Test mode” Figure 92, page 66. — FreeStyle™ 80: 3.5” w.c.; 2. With the boiler operating at maximum rate check that the op- erational (working) gas pressure at the inlet gas pressure test —...
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 62, 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 - Combi Ladder
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 22 Wiring diagram — Combi Ladder FreeStyle Figure 68 ™ 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 53: Wiring Diagram - Combi Schematic
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 22 Wiring diagram — Combi Schematic FreeStyle ™ Part number 550-142-850/0115...
Page 54: Wiring Diagram - Heating Only Ladder
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 23 Wiring diagram — Heating Only Ladder FreeStyle Figure 70 ™ NOTES: All wiring must be installed in accordance with N.E.C. and any other national state or local requirements. Room thermostat should...
Page 55: Wiring Diagram - Heating Only Schematic
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 23 Wiring diagram — Heating Only Schematic FreeStyle Figure 71 ™ Part number 550-142-850/0115...
Page 56: Controls And Operation
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 24 Controls and operation Control Introduction FreeStyle Thanks to the microprocessor control and adjustment system automatic. The system heating temperature is automatically on Natural gas or Liqueﬁed Petroleum (Propane) gas, generating governed by the control system.
Page 57 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 24 Controls and operation (continued) Central heating operation the radiator (Items 13 and 14 - Figure 72, page 56). The display indicates the actual Central Heating water temperature (Item 11 - Figure 72, page 56) and when the required temperature is reached “d2”...
Page 58 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 24 Controls and operation (continued) Ignition operation Ensure the power is on to the boiler Figure 76 Turning off Figure 72, page 56 Figure 77 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 59 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 24 Controls and operation (continued) Adjustments Figure 78 To set the system Heating temperature, use the CH buttons, “-” to reduce water setpoint “+” to increase water setpoint (Items 3 and 4 - Figure 72, page 56 To set the Domestic hot water temperature, use the DHW buttons, “-”...
Page 60 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 24 Controls and operation (continued) Adjustments Theory of Outdoor Reset Control Figure 80 space. ture. These scale ranges are related to the outdoor tem- radiation. These “Outdoor Reset Control” curves are graphed (and programmed into the control board) by outside 3.
Page 61: Dhw Settings (Combi Only)
This continues until the DHW call ends or the minutes. OUTSIDE AIR TEMPERATURE (°F) 1. The FreeStyle™ control will regulate boiler ﬁring to provide Figure 83 outlet water at this temperature. 2. For most DHW applications, set this to 190°F. A lower supply temperature can be used, but will reduce the indirect water heater heating capacity.
Page 62: High Altitude
CIRCULATOR EXERCISING Figure 88 and FREEZE PROTECTION High Altitude Fan Speed Hz CIRCULATOR EXERCISING Model Ignition High Fire 1. The FreeStyle ™ control will automatically start the cir- (Can't High Fire Change Fire - Needs CH Mode Mode (B06) (B05)
Page 63: Startup
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 27 Startup Clean system to remove sediment against lowest likely temperature the system water will en- exchanger can be damaged by buildup or corrosion due to counter). sediment. moﬂo. See Figure 149, page 109 Follow instructions supplied with the X400 cleaner ponents, including the expansion tank and boiler.
Page 64 — 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 65: 6Wduwxs ² ¿Qdo Fkhfnv
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 28 6WDUWXS ² ¿QDO FKHFNV Check for gas leaks each thermostat, zone valve and relay in the external circuits one at a time and check the voltmeter reading across the in- coming wires.
Page 66 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. ❏ 3. Are thermostats set below room temperature? FreeStyle control, and that it displays correctly.
Page 67 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 28 6WDUWXS ² ¿QDO FKHFNV (continued) FreeStyle Part number 550-142-850/0115...
Page 68 FreeStyle™ boilers are shipped ready to ﬁre natural gas ONLY. c. Calculate gas input: Failure to comply could result in severe personal injury, 3600 x 1000 death or substantial property damage.
Page 69 — 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 95 be below 0.2% or above 1%.
Page 70 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 28 6WDUWXS ² ¿QDO FKHFNV (continued) Re-check the Minimum Rate At Minimum Rate: 1. Adjust the boiler to minimum output and allow the boiler to stabilize. Figure 97 - cup B) Torx...
Page 71: 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 72: 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. FreeStyle Monthly 6 months Part number 550-142-850/0115...
Page 73: Annual Startup
HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS in addition to routine annual The FreeStyle™ heat exchanger relevant seals; c. The operational (working) gas inlet pressure at Ceramic ﬁbers can be converted to maximum rate, as described on pages 49 and 69;...
Page 74 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 31 Annual startup (continued) Check ignition wiring The boiler should be inspected and started 1. Check ignition cable electrical resistance. A good cable will season, only by a qualiﬁed service technician.
Page 75 — 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 100.
Page 76 — 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 77: Troubleshooting
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING VERIFY PROPER OPERATION AFTER SERVICING BEFORE TROUBLESHOOTING — BEFORE TROUBLESHOOTING — BEFORE TROUBLESHOOTING — BEFORE TROUBLESHOOTING — FreeStyle the “ ™ ” (page 120). Record the boiler size and CP to boiler.
Page 78 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) Check ignition sequence Figure 102 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 79: Checking Temperature Sensors
(see pages 56 to 60 Fuse located on rear of circuit board structions. a FreeStyle ™ 80 or 120, and 255 on high ﬁre, reading at signal drops below this level, the FreeStyle ™ control will attempt to correct by increasing the blower speed to increase ﬂame signal.
Page 80 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle ™ control diagnosis FreeStyle 1. The ™ boiler control Table 3 or 4 A” see Table 3): to restore operation, press the RESET button (Item 6 - Figure 72, page 56 F”, see Table 3) cause temporary shutdowns that are automatically reset as soon as the...
Page 81 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 106 (continued) Fault Code Fault Condition Correction &KHFN WKH UHJXODU JDV ÀRZ WR WKH ERLOHU DQG No burner ignition No gas that the air has been eliminated from the pipes...
Page 82 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 107 (continued) Fault Code Fault Condition Correction Delivery sensor 2 fault Sensor damaged Check the wiring or replace the sensor Wiring shorted Wiring disconnected Fan fault...
Page 83 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 108 (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 84 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle (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. In case sensor is back to the normal operating range, error is gone. In error mode, heat GHPDQGV ZLOO EH GLVDEOHG ,Q FDVH RU PRUH VHQVRUV DUH EURNHQ FRQWUROOHU ZLOO SLFN XS WKH ¿UVW WKDW ZDV RXWVLGH...
Page 85 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 110 (continued) Display Condition FAULT 39 = Outside sensor out of normal operating range (short circuit or open circuit). If sensor goes in short circuit and this condition lasts for more than 10 seconds, error is generated.
Page 86 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 111 Conﬁguration mode The display starts with showing “ parameters; between “ ” and “b26 it is possible to adjust his value (not ﬂashing). The value is automatically saved.
Page 87 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 112 Installer mode “tS” or “In” or “Hi” or “rE”. “tS” means “Transparent parameter”; “In” means “Inquiry”; “Hi” means “History”; “rE” means “Reset”. blinking Transparent parameter mode...
Page 88 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 114 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 89 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 115 Parameter Description Default Note 1RW LPSOHPHQWHG '+: FRQ¿J DHW conf. dependent '+: VORSH FRQWURO ƒ)PLQ '+: FRQ¿J 1RW LPSOHPHQWHG '+: FRQ¿J '+: VORSH FRQWURO ƒ)PLQ '+: FRQ¿J ...
Page 90 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 117 blinking Actual water pressure (psi) blinking 0LQ 0D[ Actual PWM modulating Pump (%) blinking 0LQ 0D[ Actual Step of Triac mod. mode (Num) blinking $FWXDO )ODPH &XUUHQW X$ ...
Page 91 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle (continued) System Parameters list (default settings) There are 4 basic conﬁgurations within the DHW mode, selected by parameter DHW conﬁguration (see Parameters list, Num. to 46 (see Parameters list). All the parameters can be accessed with a communication package running on the PC. Some param-...
Page 92 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 120 (continued) Category Unit Description Num. Address Description High Value '+: FRQ¿J 36,1 ML – 8104 CH supply for CH pump over-run OFF °F '+: FRQ¿J 37,1 CL5 –...
Page 93 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 121 (continued) Category Unit Description Num. Address Description High Value '+: FRQ¿J 42,2 ML – 810A DHW set point limit – LOW °F '+: FRQ¿J 43,2 CL5 –...
Page 94 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 122 (continued) Category Unit 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 95 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 123 (continued) Category Unit Description Num. Address Description High Value Central Heating CL5 – 059D CH pump selection Central Heating CL5 – 0592 CH slope control °F/min...
Page 96 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 124 (continued) Category Unit Description Num. Address Description High Value History ML – 8061 Total num. of hours with power supply ON -LSB History ML – 8060 Total num.
Page 97 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 125 (continued) Category Unit Description Num. Address Description High Value Flame current supervi- ML – 80D5 Flame current on level1 offset sion Flame current supervi- ML – 80DB...
Page 98 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 32 Troubleshooting (continued) FreeStyle Figure 126 (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...
Page 99: Maintenance
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance Clean condensate trap Disconnect power 1. See Figure 127. 2. Disconnect top cleanout cap nut that secures the trap body to Electrical shock hazard — Disconnect the boiler condensate connection.
Page 100 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Figure 131 2. Remove two (2) Phillips head screws securing the ignition electrode to the boiler heat exchanger. Use care when removing and handling igniter. necessary. 5. Inspect the ignitor ceramic and electrodes.
Page 101 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Figure 133 Figure 135 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 102 — 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 136 and 140. 2. Use a 10mm wrench or socket to remove the ﬁve (5) nuts that Figure 138 secure the burner cover plate to the heat exchanger.
Page 103 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Procedure For Cleaning Of Internal Heat Figure 140 Exchanger Circuit scale, sludge, metal oxides and, in low temperature systems, also biomass in the heat exchanger water circuit. sionally qualiﬁed personnel, in compliance with the current Do not carry out any operation on the sealed control parts.
Page 104 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Actions For Cleaning Of Heat Exchanger Procedure for chemical cleaning of DHW Water Circuit circuit struction booklet. Chemical cleaning and maintenance must be carried out by pro- not carry out any operation on the sealed control parts.
Page 105 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Hot Water Can Scald! is austenitic stainless steel, class AISI 316. 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 106 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) Figure 145 placed next to the CH return (5), see Figure 144. Release Heat Exchanger pressure in the boiler by to heat exchanger return. Figure 143 The direction of arrows on heat exchanger.
Page 107 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 33 Maintenance (continued) 20. Reconnect the unit to the electrical power supply us- Figure 147 turn it ON. DHW Outlets DHW Inlets (diverter valve) disposal. 13. The cleaned brazed plate heat exchanger can now be installed.
Page 108: 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 109 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) M&G Simpson-Duravent PolyPro SIDEWALL concentric vent/air kit (color: white) Antifreeze, Sentinel X500 ... 592-900-004WT 2” polypropylene pipe ... .
Page 110 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) FreeStyle Figure 150 Item Name Part Number Jacket door 640-000-002WT Jacket left side 640-000-000WT Jacket right side 640-000-001WT Part number 550-142-850/0115...
Page 111 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) FreeStyle Figure 151 Part number 550-142-850/0115...
Page 112 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) FreeStyle Figure 152 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 640-000-014WT Central Heat Exchanger Insulation...
Page 113 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) FreeStyle Figure 153 Combi ) continued Part number 550-142-850/0115...
Page 114 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) FreeStyle Figure 154 Model Item Name Part Number 640-000-008WT Heat Exchanger 640-000-008WT Flue Sensor Temperature 640-000-011WT Blower Assembly 640-000-020WT Blower Gasket 640-000-021WT Ignitor 640-000-014WT Central Heat Exchanger Insulation...
Page 115 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) FreeStyle Figure 155 ) continued Part number 550-142-850/0115...
Page 116 — FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts (continued) FreeStyle Figure 156 Item Name Part Number Control module assembly 640-000-003WT Control module display cover 640-000-004WT Pressure-Temperature assembly - Combi 640-000-006WT Pressure-Temperature assembly - Heating Only 640-000-054WT...
Page 117: Dimensions And Connections Data
— FreeStyle OUNT GAS FIRED WATER BOILER Boiler Manual 35 Dimensions and connections data FreeStyle Figure 157 Heating 1 Heating system supply tapping — ¾” NPT 1 Heating system supply tapping — ¾” NPT 3 Gas connection 2 Domestic hot water outlet 5 Heat system return tapping —...
Page 118: Engineering Data
0.55 2” or 3” 15.0 amps total. FreeStyle™ 80 or 120 vent/air pipes can be either 2” or 3” pipe. through the piping. See Figure 159, page 119 All FreeStyle™ . Install and terminate vents as described in vent/air installation instructions in this manual.
Page 119: Ratings
NOTE that only Heating Capacity and FreeStyle™ 80 or 120 vent/air pipes can piping. For vent/air pipe lengths less AFUE are certiﬁed by AHRI. AFUE is be either 2” or 3”.
Page 120: Qvwdoodwlrq Dqg 6Huylfh &Huwl¿Fdwh
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