Freestyle FS-80 NG User manual

FreeStyle™
Wall Mount Gas-Fired
Central Heating Water Boilers
80/120
Boiler Manual
* Low Lead Content
Part number 550-142-850/0115
This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in
severe personal injury, death or substantial property damage.
 7HENCALLINGORWRITINGABOUTTHEBOILER0LEASEHAVEsBOILERMODELNUMBERFROMTHEBOILERRATINGLABEL
Available in the Combi or Heating only models
* CSA - Low Lead Content only applies to the Combi model
Quick Start
Guide
Pages 3 & 4
s)NSTALLATION
s3TARTUP
s-AINTENANCE
s0ARTS

Part number 550-142-850/0115
2
FreeStyle™WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
INSTALLER — 2EADALLINSTRUCTIONSBEFORE
installing. Read page 3 first. Follow all instruc-
tions in proper order to prevent personal injury
or death.
s #ONSIDERPIPINGANDINSTALLATIONWHENDETERMINING
BOILERLOCATION
s !NYCLAIMSFORDAMAGEORSHORTAGEINSHIPMENT
MUSTBElLEDIMMEDIATELYAGAINSTTHETRANSPORTA-
TIONCOMPANYBYTHECONSIGNEE
USER 0LEASEREADTHEFOLLOWING&AILURETO
comply could result in severe personal injury,
death or substantial property damage.
s This manual is for use only by your qualified
HEATINGINSTALLERSERVICETECHNICIAN
s 0LEASESEETHE5SERS)NFORMATION-ANUALFORYOUR
REFERENCE
s (AVE THE BOILER SERVICED BY A QUALIlED SERVICE
TECHNICIANATLEASTANNUALLY
Hazards that will or can cause minor personal
injury or property damage.
Special instructions on installation, operation or
maintenance that are important but not related to
personal injury or property damage.
Hazards that will cause severe personal injury, death
or substantial property damage.
Hazards that can cause severe personal injury, death
or substantial property damage.
Hazard definitions
Contents Page
1 Quick Start Guide — using default settings . . . . . . . 3
2 Prepare boiler location . . . . . . . . . . . . . . . . . . 6
3 Prepare boiler . . . . . . . . . . . . . . . . . . . . . . . 8
4 Converting boiler to propane . . . . . . . . . . . . . 12
5 Gas piping — sizing gas lines . . . . . . . . . . . . . 16
6 Venting/air piping — general. . . . . . . . . . . . . . 17
7 Commonwealth of Massachusetts installations . . . 20
8 Vent termination requirements. . . . . . . . . . . . . 21
9 Boiler room air openings . . . . . . . . . . . . . . . . 22
10 DIRECT VENT — Sidewall with separate pipes . . . 23
11 DIRECT VENT — Sidewall concentric . . . . . . . . 25
12 DIRECT VENT — Vertical with separate pipes. . . . 27
13 DIRECT VENT — Vertical concentric. . . . . . . . . 29
14 Concentric termination, typical (sidewall or vertical) . . 31
15 Vent and air piping and boiler connections . . . . . 32
16 Install water piping . . . . . . . . . . . . . . . . . . 35
Domestic Water Piping – Combi Boiler . . . . . . . 35
17 Primary/Secondary System Piping . . . . . . . . . . . . . . . . 37
System water piping methods . . . . . . . . . . . . 37
Expansion Tank Location . . . . . . . . . . . . . . 37
Diaphragm- or bladder-type tank: . . . . . . . . . . 37
Closed-type expansion tank: . . . . . . . . . . . . 39
Install relief valve . . . . . . . . . . . . . . . . . . . 40
Zone Valve zoning – primary/secondary . . . . . . . 41
Circulator zoning – primary/secondary . . . . . . . 42
Circulator zoning – Multiple temperature zones with
primary/secondary . . . . . . . . . . . . . . . . . . 43
18 Multiple boiler installations . . . . . . . . . . . . . . 44
19 Install condensate line . . . . . . . . . . . . . . . . 47
20 Gas piping . . . . . . . . . . . . . . . . . . . . . . . 48
21 Field wiring. . . . . . . . . . . . . . . . . . . . . . . 50
22 Wiring diagram — Combi Ladder. . . . . . . . . . . 52
22 Wiring diagram — Combi Schematic. . . . . . . . . 53
23 Wiring diagram — Heating Only Ladder . . . . . . . 54
23 Wiring diagram — Heating Only Schematic . . . . . 55
24 Controls and operation . . . . . . . . . . . . . . . . 56
25 DHW Settings (Combi Only) . . . . . . . . . . . . . . 61
26 High Altitude . . . . . . . . . . . . . . . . . . . . . . 62
27 Startup . . . . . . . . . . . . . . . . . . . . . . . . . 63
6WDUWXS²¿QDOFKHFNV . . . . . . . . . . . . . . . . 65
&KHFNRXWVWDUWXSYHUL¿FDWLRQ . . . . . . . . . . . . 71
30 Annual startup and general maintenance . . . . . . 72
31 Annual startup . . . . . . . . . . . . . . . . . . . . . 73
32 Troubleshooting . . . . . . . . . . . . . . . . . . . . 77
33 Maintenance . . . . . . . . . . . . . . . . . . . . . . 99
34 Replacement parts . . . . . . . . . . . . . . . . . 108
35 Dimensions and connections data . . . . . . . . . 117
36 Engineering Data . . . . . . . . . . . . . . . . . . 118
37 Ratings . . . . . . . . . . . . . . . . . . . . . . . . 119
,QVWDOODWLRQDQG6HUYLFH&HUWL¿FDWH. . . . . . . . . 120

Part number 550-142-850/0115 3
FreeStyle™WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
1 Quick Start Guide — using default settings
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.
All water piping, heating (and domestic if a Combi boiler) is installed correctly and free of leaks with the proper
accessories; proper sized expansion tank, water feed valve adjusted, low water cut-off devices installed and tested,
all operation control exterior to the boiler installed such as thermostats, and zone control panels.
s 3ENTINEL8)NHIBITORHASBEENADDEDANDTHEWATERHASBEENCHECKEDWITHTHESUPPLIEDTESTKIT
s #ONDENSATETRAPHASBEENlLLEDWITHWATER
s %LECTRICALCONNECTIONFORTHEBOILERISGROUNDEDANDHASCORRECTPOLARITY
s 6ENTINGAND)NTAKE!IR0IPINGISALLSECURESEALEDANDINSTALLEDASINSTRUCTEDINTHEBOILERMANUAL
s #ENTRal Heating only boilers, outdoor sensor MUST be installed and connected to the boiler control.
(See boiler manual)
System start
1
Push ECO / Comfort / Power button; to start boiler
2
NOTE: if A-16 error code is displayed (Central Heating Only boiler) when unit is powered up, the outdoor sensor is not
installed. Install outdoor sensor and push the reset button to reset error code. A faulty outdoor sensor will give an“F-39”
error code.
4HEOUTDOORSENSORMUSTBEINSTALLEDUNLESSSPECIlCALLYEXEMPTEDINTHE%NERGY!CTSTATEMENTONPAGE.
3
01 “shows on the display” (control software version)
4
FH “shows on the display” (Fan /inducer operating in purge mode of combustion chamber and venting for 300 seconds).
5
With no“call for heat” (current boiler water temperature will be shown in degrees F).
6
To Change “Central Heating water temperature set-point” (from 68 F to 194 degrees F) use the bottom set of “+”or “–” keys to
raise or lower the set point temperature.
7
To change “Domestic water temperature set-point” (Combi Boiler) ( from 104 F to 131 degrees F ) NOTE: Insure that operating
temperature is a safe set-point temperature. Use the top set of “+”or “–” keys to raise or lower the set point.
Figure 1 1UICK3TART'UIDE$EFAULTCONTROLSETTINGSSEEINSTRUCTIONSANDlGURESONPAGES56-61

Part number 550-142-850/0115
4
FreeStyle™WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
QUICK START GUIDE
System start (continued)
8
“Test Mode Operation”
0ROCEEDTOPUTTHEBOILERINTOOPERATIONASFOLLOWS
1. To operate the boiler in test mode, press the CH “-” and “+” KEYSTOGETHER FOR SECONDS
(See below and Figure 92, page 66) to activate the TEST mode.
2. The boiler lights at the maximum heating 100% rate displayed on the LCD display.
3. The high fire (large) flame symbol will be displayed once the boiler has lit.
4. Use DHW “_” button to drop firing rate to low fire.
5. To exit the “Test mode”, press the CH keys (Items 3 and 4 Figure 72, page 56TOGETHERFORSECONDSOR
LEAVETHEBOILERTOAUTOMATICALLYSWITCHOFFAFTERMINUTESORSTOPPING$(7mOW
6. This TEST procedure is used to check/adjust combustion CO and CO2 per specifications, Figure 95, page 69
and Figure 98, page 70.
Liquefied Petroleum (Propane) Gas — Propane conversion kit (optional - sold separately, see Figure148,page108 .
High altitude — High altitude (over 4,500 feet) requires only changing the altitude setting on the control.
Equipment that maybe required for installation
Digital or U-tube manometer for checking gas line pressure
Volt-ohmmeter may be required for troubleshooting
Combustion Analyzer to verify and adjust combustion
1 Quick Start Guide — using default settings

Part number 550-142-850/0115 5
FreeStyle™WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
Failure to adhere to the guidelines below can
result in severe personal injury, death or sub-
stantial property damage.
)NSTALLER— Read all instructions, including
THISMANUALANDALLOTHERINFORMATIONSHIPPED
WITHTHEBOILERBEFOREINSTALLING0ERFORMSTEPS
in the order given.
User 4HIS MANUAL ISFORUSE ONLY BYA
qualified heating installer/service technician.
2EFERTO5SERS)NFORMATION-ANUALFORYOUR
REFERENCE
User — Have this boiler serviced/inspected by
a qualified service technician, at least annually.
4HISUNITMUSTONLYBEUSEDFORITSINTENDED
purpose. This unit is designed to heat water to
a temperature below boiling point and must
be connected to a heating system and/or a
WATERSUPPLYSYSTEMFORDOMESTICUSECOM-
PATIBLEWITHITSPERFORMANCECHARACTERISTICS
and heating capacity.Any other use is deemed
improper.
Incorrect installation can cause damage or
INJURYFORWHICHTHEMANUFACTURERCANNOTBE
deemed responsible.
The boiler contains ceramic fiber and
fiberglass materials. Use care when handling
these materials per instructions on page 73
OFTHISMANUAL&AILURETOCOMPLYCOULD
result in severe personal injury.
Pay attention when handling the boiler insu-
lation panels as they contain materials that
COULDIRRITATETHESKIN.OPARTOFTHEBOILER
CONTAINSASBESTOSMERCURYOR#&#S
Consider piping and installation when deter-
mining boiler location.
 !NYCLAIMSFORDAMAGEORSHORTAGEINSHIP-
ment must be filed immediately against the
transportation company by the consignee.
When servicing boiler —
1. To avoid electric shock, disconnect electrical supply
BEFOREPERFORMINGMAINTENANCE
 4OAVOIDSEVEREBURNSALLOWBOILERTOCOOLBEFOREPER-
FORMINGMAINTENANCE
3. This boiler contains ceramic fiber and fiberglass materi-
ALS2EFERTOTHE7!2.).'ANDINSTRUCTIONSONpage 73.

#OMMONWEALTHOF-ASSACHUSETTS
)F THE BOILER IS INSTALLEDWITHINTHE#OMMONWEALTHOF
-ASSACHUSETTS
s This product must be installed by a licensed plumber or
gas fitter.
s )F ANTIFREEZEISUSEDAREDUCEDPRESSUREBACKmOWPRE-
venter device shall be used.
s Sidewall vent air installations — see instruction on
page 20.
"OILEROPERATION
1. $ONOTBLOCKmOWOFCOMBUSTIONORVENTILATIONAIRTO
boiler.
2. 3HOULDOVERHEATINGOCCUROR GAS SUPPLYFAIL TO SHUT
OFFDONOTTURNOFFORDISCONNECTELECTRICALSUPPLYTO
CIRCULATOR)NSTEADSHUTOFFTHEGASSUPPLYATALOCATION
external to the appliance.
3. $ONOTUSETHISBOILERIFANYPARTHASBEENUNDERWATER
Immediately call a qualified service technician to inspect
THEBOILERANDTOREPLACEANYPARTOFTHECONTROLSYSTEM
and any gas control that has been under water.
#!2"/.-/./8)$%$%4%#4/2
s A carbon monoxide detector that is wired on the
same electrical circuit as the boiler is strongly recom-
mended.
* In some locations, a carbon monoxide detector is
required by the law.
352'%02/4%#4/2
s Provide surge protection in the boiler power supply.
4HISWILLREDUCETHEPOSSIBILITYOFDAMAGETOTHEBOILER
control.
"OILERWATER
s 4HEHEATEXCHANGERISMADEOFSTAINLESSSTEELANDREQUIRES
that system water chemistry to be within the limits in
this manual. Use the Sentinel X100 inhibitor supplied
with boiler. !$$)4)/.!,#(%-)#!,42%!4-%.4-!9
"%.%#%33!29. See page 63FORDETAILS
s Thoroughly flush the system ("%&/2% connecting
BOILERTO REMOVESEDIMENT4HE HIGHEFlCIENCYHEAT
exchanger can be damaged by build-up or corrosion
due to sediment.
&2%%:%02/4%#4)/.&,5)$3
s Thoroughly clean and flush any replacement boiler sys-
TEMTHATHASUSEDGLYCOLBEFOREINSTALLINGTHENEWBOILER
Use only the products listed by Williamson-Thermoflo
FORUSEWITHTHISBOILER3EEpage 109FORDETAILS

Part number 550-142-850/0115
6
FreeStyle™WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
Installations must comply with:
s Local, state, provincial, and national codes, laws, regulations
and ordinances.
s .ATIONAL&UEL'AS#ODE!.3):.&0!
s National Electrical Code.
#ERTIlCATION
The FreeStyle™BOILERGASMANIFOLDANDCONTROLS
METSAFE LIGHTINGAND OTHERPERFORMANCECRITERIA
WHENBOILERUNDERWENTTESTSSPECIFIED IN!.3)
:LATESTEDITION
Flooring
1. The boiler must not be installed on carpeting.
$ONOTINSTALLBOILERONCARPETINGEVENIFFOUNDA-
tion is used. Fire can result, causing severe personal
injury, death or substantial property damage.
"EFORELOCATINGTHEBOILER
1. 7ALL CONSTRUCTION  -AKESURETHEWALL CONSTRUCTION IS
SUITABLETOCARRYTHEWEIGHTOFTHEBOILERANDCOMPONENTS
See page 9FORINSTRUCTIONS
2. 4HEBOILERISSUITABLEFOR).$//2INSTALLATION only.
3. #HECKFORNEARBYCONNECTIONTO
s System water piping
s Venting connections
s 'ASSUPPLYPIPING
s Electrical power
s Condensate drain
4. Check area around boiler. Remove any combustible materials,
gasoline and other flammable liquids.
&AILURETOKEEPBOILERAREACLEARANDFREEOFCOMBUS-
tible materials, gasoline and other flammable liquids
and vapors can result in severe personal injury, death
or substantial property damage.
5. The
FreeStyle™boiler must be installed so that gas control
SYSTEMCOMPONENTSAREPROTECTEDFROMDRIPPINGORSPRAYING
water or rain during operation or service.
6. )FNEWBOILERWILLREPLACEEXISTINGBOILERCHECKFORANDCORRECT
system problems, such as:
s Sediment or corrosion in system piping — clean and flush
piping BEFORE connecting the new boiler. See page 63.
s System leaks causing oxygen corrosion or heat exchanger
CRACKSFROMHARDWATERDEPOSITS
s Incorrectly-sized expansion tank.
s ,ACKOFFREEZEPROTECTIONINBOILERWATERCAUSINGSYSTEM
ANDBOILERTOFREEZEANDLEAK
Residential garage installation
0RECAUTIONS
1. 4AKETHE FOLLOWING SPECIALPRECAUTIONS WHENINSTALLING THE
BOILERINARESIDENTIALGARAGE)FTHEBOILERISLOCATEDINARESI-
dential garage:
s -OUNTTHEBOILERWITHITSBOTTOMATLEASTINCHESABOVE
THEmOOR4HISCOMPLIESWITHTHE.ATIONAL&UEL'AS#ODE
!.3):FOR53INSTALLATIONSOR#3!"
s Locate or protect the boiler so it cannot be damaged by
a moving vehicle.
s Ensure that the installation complies with all applicable
codes.
s 0REVENTBOILERWATERANDCONDENSATEFROMFREEZING
Provide air openings to room
FreeStyle™boiler alone in boiler room
1. .OAIRVENTILATIONOPENINGSINTOBOILERROOMARENEEDEDIF
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.
%ACHOPENINGMUSTPROVIDESQUAREINCHFREEAREAPER
"TUHOFBOILERINPUT
FreeStyle™BOILERINSAMESPACEWITHOTHER
GASOROILlREDAPPLIANCES
1. Follow the sizing requirements shown in Figure 23, page 22.
2 Prepare boiler location
Codes & checklist
The space must be provided with combustion/
VENTILATIONAIR OPENINGS CORRECTLYSIZED FORALL
appliances located in the same space as the
FreeStyle ™ boiler.
2EINSTALLBOILERJACKETDOORAFTERSERVICING4HE
BOILERJACKETDOORMUSTBESECURELYFASTENEDTO
THEBOILERTO PREVENTBOILER FROMDRAWING AIR
FROMINSIDETHEBOILERROOM4HISISPARTICULARLY
IMPORTANT IFTHE BOILER IS LOCATEDIN THE SAME
room as other appliances.
Failure to comply with the above warnings
could result in severe personal injury, death or
substantial property damage.
Vent and air piping
1. The FreeStyle™boiler requires a special vent system, designed
FORPRESSURIZEDVENTINGFreeStyle™boilers are rated ANSI
:$IRECT6ENTPRESSURIZEDVENTLIKELYTOCONDENSEIN
the vent). See instructions beginning on page 17.
2. 9OUMUST ALSOINSTALLAIR PIPING FROMOUTSIDE TOTHE BOILER
air intake adapter. The resultant installation is categorized as
DIRECTVENTSEALEDCOMBUSTION.OTEPREVENTIONOFCOMBUS-
tion air contamination on page 8 when considering vent/air
termination.
3. Vent and air must terminate near one another unless otherwise
specified in this manual. Vent and air piping may be routed
VERTICALLYTHROUGHTHEROOFOROUTASIDEWALLFOLLOWINGTHE
OPTIONSGIVEINTHISMANUAL9OUMAYUSEANYOFTHEVENTAIR
piping methods covered in this manual. Do not attempt to
install the FreeStyle™boiler using any other means.
4. Be sure to locate the boiler such that the vent and air piping
can be routed through the building and properly terminated.
The vent/air piping lengths, routing and termination method
must all comply with the methods and limits in instructions
beginning on page 17.

Figure 2 REQUIREDMINIMUMCLEARANCES
(ALLDIMENSIONSAREININCHES)
Part number 550-142-850/0115 7
FreeStyle™WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
2 Prepare boiler location continued
Provide clearances from
combustible materials — REQUIRED
1. See Figure 2FOR 2%15)2%$MINIMUMCLEARANCES!,,
installation must provide at least these minimums.
2. (OTWATERPIPESATLEASTvFROMCOMBUSTIBLEMATERIALS
3. Vent pipe — at least ³⁄₁₆vFROMCOMBUSTIBLEMATERIALS
4. 3EE&IGUREFORSERVICECLEARANCEMINIMUMS
 )FTHEUNITISENCLOSEDINACABINETORMOUNTED
ALONGSIDEASPACEMUSTBEPROVIDEDFORREMOV-
INGTHECASING AND FOR NORMAL MAINTENANCE
operations. The minimum measurements to be
respected are given in Figure 2.
Provide clearances for service
access — RECOMMENDED
1. See Figure 2,FORRECOMMENDEDSERVICECLEARANCES
2. )FYOUDONOTPROVIDEMINIMUMSERVICECLEARANCESSHOWNIT
might not be possible to service the boiler without removing
ITFROMTHESPACE
3. Clearance D, Figure 2ALLOWSFORTHEINSTALLATIONOFPIPING
as shown in Figure 6, page 11, plus a union, close nipple
and elbow.
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,
then the enclosure MUST HAVE air openings located per Figure 2,
above.Each of these air openings must have free area of at least
1 square inch per 1,000 MBH of boiler input.
B Left side clearance to combustibles = 1.0 inches minimum
C Top of boiler clearance to combustibles = 12.0 inches minimum
D Right side clearance to combustibles = 1.0 inches minimum
E Bottom of boiler clearance to combustibles = 12 inches minimum
(must be 18 inches above floor for garage installations)
F Clearance in front of the boiler = 12.0 inches,but 36 inches mini-
mum required for service
H Vent pipe must be minimum 3/16 inch from combustibles.Opening
in combustible wall, floor, ceiling or roof must be 3/8”larger than
flue pipe diameter,fitted with galvanized steel thimble, or larger if
required by codes or as specified by vent pipe manufacturer.
ADDITIONAL service clearance may be
needed, depending on how piping is routed
to the boiler.
A Provide combustion air/ventilation openings per Figure 23,page 22 or as
otherwise directed in this manual or by applicable codes.NOTE: If the instal-
lation does not provide the minimum clearances in this illustration, then the
enclosure must have air openings located and sized per Figure 2.
B Left side service clearance = 36 inches minimum
C Service clearance above top of boiler = 24 inches minimum
D Right side service clearance = 24 inches minimum
E Service clearance below the boiler = 36 inches minimum
F Service clearance in front of the boiler = 36 inches minimum
Minimum
required
for
Combustion
A Minimum 1.00”
B Minimum 12.00”
C Minimum 12.00”
D Minimum 12.00”
Recommended
for
Service
A Minimum 36.00”
B Minimum 36.00”
C Minimum 24.00”
D Minimum 36.00”

Part number 550-142-850/0115
8
FreeStyle™WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
Remove boiler from crate
The boiler is heavy. Use caution not to drop the
BOILERORCAUSEBODILYINJURYWHILELIFTINGANDHAN-
DLING6ERIFYTHATTHEBOILERISSECURELYATTACHEDTO
PREVENTPOSSIBILITYOFBOILERFALLINGAFTERINSTALLATION
Do not drop boiler or bump jacket on floor or pallet.
Damage to boiler can result.
 #OLDWEATHERHANDLING)FBOILERHASBEENSTORED
INAVERYCOLDLOCATIONBELOW&BEFOREINSTALLA-
tion, handle with care until the plastic components
come to room temperature.
1. 4HEBOILERISGENERALLYEASIERTOHANDLEANDMANEUVERAFTER
removing the shipping container.
2. ,EAVETHEBOILERRESTINGONTHESTYROFOAMPROTECTIVEBASE
and bottom cardboard cap, until ready to place on the wall.
4HEBOILERISARRANGEDANDDESIGNEDFORWALL
mounting and comes standard with a hanging
bracket. The wall fixing must ensure stable and
EFFECTIVESUPPORTFORTHEBOILER
0LEASEREVIEWTHEFOLLOWINGINFORMATIONONPOTENTIALCOMBUSTION
air contamination problems.
See Table 1FORPRODUCTSANDAREASWHICHMAYCAUSECONTAMINATED
combustion air.
 4OPREVENTPOTENTIALOFSEVEREPERSONALINJURYOR
DEATHCHECKFORPRODUCTSORAREASLISTEDBELOWBE-
FOREINSTALLINGBOILER)FANYOFTHESECONTAMINANTS
AREFOUND
s REMOVECONTAMINANTSPERMANENTLY
   /2
s ISOLATEBOILERANDPROVIDEOUTSIDECOMBUSTIONAIR
3EENATIONALPROVINCIALORLOCALCODESFORFURTHER
INFORMATION
Air contamination
Table 1 Corrosive contaminants and likely
9OUMUSTPIPECOMBUSTIONAIRTOTHEBOILER
AIRINTAKE.
)NSTALLAIRINLETPIPINGFORTHEFreeStyle™boiler as
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.
Ensure that the combustion air will not contain
ANYOFTHECONTAMINANTSIN4ABLE$ONOTPIPE
COMBUSTIONAIRNEARASWIMMINGPOOLFOREXAMPLE
!VOIDAREASSUBJECTTOEXHAUSTFUMESFROMLAUNDRY
FACILITIES4HESEAREASWILLALWAYSCONTAINCONTAMI-
nants.
Contaminated combustion air will damage the
boiler, resulting in possible severe personal injury,
death or substantial property damage.
3 Prepare boiler
2 Prepare boiler location continued
0RODUCTSTOAVOID
3PRAYCANSCONTAININGCHLOROmUOROCARBONS
0ERMANENTWAVESOLUTIONS
#HLORINATEDWAXESCLEANERS
#HLORINEBASEDSWIMMINGPOOLCHEMICALS
#ALCIUMCHLORIDEUSEDFORTHAWING
3ODIUMCHLORIDEUSEDFORWATERSOFTENING
2EFRIGERANTLEAKS
0AINTORVARNISHREMOVERS
(YDROCHLORICACIDMURIATICACID
#EMENTSANDGLUES
!NTISTATICFABRICSOFTENERSUSEDINCLOTHESDRYERS
#HLORINETYPEBLEACHESDETERGENTSANDCLEANINGSOLVENTSFOUNDIN
HOUSEHOLDLAUNDRYROOMS
!DHESIVESUSEDTOFASTENBUILDINGPRODUCTSANDOTHERSIMILAR
PRODUCTS
%XCESSIVEDUSTANDDIRT
!REASLIKELYTOHAVECONTAMINANTS
$RYCLEANINGLAUNDRYAREASANDESTABLISHMENTS
3WIMMINGPOOLS
-ETALFABRICATIONPLANTS
"EAUTYSHOPS
2EFRIGERATIONREPAIRSHOPS
0HOTOPROCESSINGPLANTS
!UTOBODYSHOPS
0LASTICMANUFACTURINGPLANTS
&URNITURERElNISHINGAREASANDESTABLISHMENTS
.EWBUILDINGCONSTRUCTION
2EMODELINGAREAS
'ARAGESWITHWORKSHOPS

Figure 3 !DDITIONOFRUBBERBUMPERFOR WALLMOUNTING
2 inches
14 inches-center to center of rubber
Part number 550-142-850/0115 9
FreeStyle™WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
5. Remove the mounting bracket and drill holes 1/4”diameter
by 3 inches deep, centered on the screw slot outlines. (For
metal stud walls, using 3/16” toggle bolts, drill required
clearance holes.)
Place boiler on bracket
1. 4HEWALLMOUNTBRACKETMUSTBEINSTALLEDBEFOREMOUNTING
the boiler.
2. !FTERINSTALLINGTHE BOILER ON THE MOUNTINGBRACKETBEND
down the two (2) tabs in order to secure boiler in place,
see Figure 5.
3 Prepare boiler continued
Wall-mounting requirements
DO NOT attempt to attach the wall mount bracket
using anchors or any means other than directly
securing to the wall studs (or equivalent wood
STRUCTUREIFSTUDSARENOTONINCHCENTERS
4HEWALLMUSTBEVERTICALLYPLUMBANDCAPABLE
OFCARRYINGTHEWEIGHTOFTHEBOILERANDANYAT-
TACHEDPIPINGCOMPONENTS.
 4HEOPERATINGWEIGHTFOR WALLMOUNTABLE BOILERS ARE
FreeStyle™80: POUNDS
FreeStyle™120: POUNDS
Failure to comply with above and the procedure
given below could result in severe personal injury,
death or substantial property damage.
1. 3TUDSPACING"RACKETHOLESARESPACEDFORSTUDSONINCH
centers.For other stud spacing, provide secure, solid mounting
SURFACEONWHICHTOATTACHTHE BOILERWALLMOUNTINGBRACKET
2. Wood stud wall: Install bracket with lag screws (3/8” x 3”)
included in kit, only into the studs.
3. -ETALSTUDWALL3ECUREBRACKETANDSPACERBOARDTOSTUDS
with 3/16-inch toggle bolts and 3/16-inch flat washers (not
included with kit).
4. Concrete or block wall: Secure wall bracket with approved
BOLTSFORTHATAPPLICATION
6ERIFYTHATTHESTUDSARESUITABLEFORCARRYINGAWALL
mounted load. Some metal studs are not designed
FORTHISPURPOSE
5. )FTHEMOUNTINGWALLHASEXPOSEDSTUDSINSTALLERMUSTPROVIDE
a backer board to mount boiler. Boiler cannot be leveled
WITHOUTABACKINGSURFACE
6. -OUNTTHEBOILERONTHEWALLFOLLOWINGTHESEINSTRUCTIONS
The boiler mounting studs must engage with the wall-mount
BRACKET-AKESURETHEBRACKETISNOTJUSTRESTINGONTHEEDGE
OFTHEMOUNTINGSTUDORWASHER0ERFORMALLPROCEDURESGIVEN
INTHE "OILER -ANUALON PREVIOUS PAGESBEFOREMOUNTING
the boiler.
Install rubber bumpers to back of boiler
1. 2EMOVESUPPLIEDRUBBERBUMPERSFROMPLASTICBAGANDMEA-
SUREACROSSINCHESANDUPINCHESFROMTHEBACKOFTHE
BOILERBOTTOMEDGE-ARKTHESETWOLOCATIONSANDPEELOFF
ADHESIVEPROTECTIONFROMTHERUBBERBUMPERSANDMOUNT
the two according to the directions in Figure 3.
2. DO NOT drill holes to mount the rubber bumpers
Install the wall-mount bracket
1. Locate the studs — must be on 16-inch centers. See previ-
OUSINSTRUCTIONSIFSTUDSARENOTONINCHCENTERS
2. Place the wall-mount bracket Figure 4, below on the wall,
using a level to align correctly.
3. Place the wall-mount bracket so the mounting slots are
centered over the studs.
4. ,EVELTHEBRACKETANDTRACETHEOUTLINEOFTHESCREWSLOTS
with a pencil.
Figure 4 7ALLMOUNTBRACKET
Figure 5 7ALLMOUNTBRACKETTABSBENDOVERBOILERTO
SECUREBOILERINPLACE
6. Position the wall-mount bracket on the wall. Insert and
LOOSELYTIGHTENTHETWOLAGSCREWSORTOGGLEBOLTSFOR
metal studs).
7. Level the wall-mounting bracket. Then tighten lag screws
securely. For drywall or plaster lathe installations, avoid
tightening so much that the bracket digs into the wall
SURFACE
Bend tabs after installation

Part number 550-142-850/0115
10
FreeStyle™WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
Hydrostatic pressure test
 $/./4INSTALLARELIEFVALVEWITHAPRESSUREHIGH-
ERTHAN03)'4HISISTHEMAXIMUMALLOWABLE
RELIEFVALVESETTINGFORTHE&REE3TYLEBOILER
&AILURE TO COMPLY COULD PREVENT THE RELIEF
VALVEFROMOPERATINGASNEEDEDRESULTINGIN
POSSIBILITYOFSEVEREPERSONALINJURYDEATHOR
SUBSTANTIALPROPERTYDAMAGE
5SETWOWRENCHESWHENTIGHTENINGANYPIPE
CONNECTIONTOTHEBOILER. Failure to prevent the
BOILERPIPESFROMTURNINGCOULDDAMAGEPIPESOR
heat exchanger, resulting in possible severe personal
injury, death or substantial property damage.
0RESSURETESTTHEBOILERBEFOREPERMANENTLYATTACHINGWATEROR
gas piping or electrical supply.
Install pipe fittings for relief valve and
P/T gauge
1. Install the reducing tees, and close nipples, field supplied,
located and oriented as shown in Figure 6, page 11. Apply
pipe dope to all fittings sparingly.
$/ ./4 INSTALL THE RELIEF VALVE UNTIL AFTER THE
HYDROSTATIC TEST. Temporarily install a ¾” pipe
PLUGINTHERELIEFVALVELOCATIONASDIRECTEDINTHESE
INSTRUCTIONS4HEPLUGMUSTBEREMOVEDAFTERTHE
test.
#ONNECTTHERELIEFVALVE/.,9ONTHE"/),%2
3500,9 /54,%4 ./4 the boiler return. Con-
NECTTHERELIEFVALVEONLYASSHOWNINTHISMANUAL
%NSURERELIEFVALVEISLOCATEDABOVEHEATEXCHANGER
Failure to comply with the above could prevent
THERELIEFVALVEFROMOPERATINGASNEEDEDRESULTING
INPOSSIBILITY OFSEVEREPERSONAL INJURYDEATH OR
substantial property damage.
2. Install the test pressure/temperature gauge (field supplied)
to the reducing tee as shown in Figure 7, page 11.
Install fittings and valves required for
hydrostatic testing (supplied by installer)
1. 4HEFOLLOWINGPIPINGCOMPONENTSSUPPLIEDBYINSTALLERARE
REQUIREDFORTHETESTCONlGURATION
a. 4WOSHUTOFFVALVESÐv.04ON&3
b. Two close nipples (¾”NPT on FS-80/120,
c. ¾” NPT pipe plug.
d. Pressure/temperature gauge.
e. ¾” NPT boiler drain valve.
2. 4%-0/2!2),9INSERTAÐv.04PIPEPLUGINTHERELIEFVALVE
TAPPING!FTERTHEHYDROSTATICTESTTHISPLUGmust be removed
ANDTHERELIEFVALVEMUSTBEINSTALLED
Fill and pressure test
1. See Figure 6, page 11,FORUSEWITHTHEFOLLOWINGINSTRUCTIONS
2. CLOSE the boiler drain valve (item 10). Connect a hose to
FRESHWATERSUPPLYANDTOTHEDRAINVALVE
3. 0LACEA BUCKETUNDER THE ENDS OFTHEISOLATION VALVES
(item 8 and 9) to catch water drippings.
4. CLOSE isolation valve item 9, then crack open the valve
slightly. Leave top isolation valve item 8 open.
5. 3LOWLYOPENTHEBOILERDRAINVALVEITEMANDFRESHWATER
supply to fill boiler with water. The boiler and piping will
lLLQUICKLYBECAUSEOFTHELOWWATERCONTENT
6. 7HENWATERBEGINSTO mOWFROMBOTTOM ISOLATION VALVE
(item 9), close the valve.
7. #ONTINUElLLINGUNTILWATERmOWSFROMTOPISOLATIONVALVE
(item 8), then close the valve.
8. When pressure on the pressure/temperature gauge (item
REACHES ATLEAST 03)'BUT NO HIGHER THAN  03)'
CLOSE the boiler drain valve (item 10).
9. (OLDATTESTPRESSUREFORMINUTES
Do not leave boiler unattended. A cold water fill
could expand and cause excessive pressure, result-
ing in severe personal injury, death or substantial
property damage.
10. -AKESURECONSTANT GAUGEPRESSUREHAS BEEN MAINTAINED
THROUGHOUTTEST#HECKFORLEAKS2EPAIRIFFOUND
,EAKSMUSTBEREPAIRED AT ONCE Failure to
do so can damage boiler, resulting in substantial
property damage.
Do not use petroleum-based cleaning or sealing
COMPOUNDSIN BOILER SYSTEM'ASKETSANDSEALS
in the system may be damaged. This can result in
substantial property damage.
Drain and remove fittings
1. $ISCONNECTlLLWATERHOSEFROMWATERSOURCE
2. Drain boiler through drain valve (item 10).
 5SECAUTIONWHENRELEASINGPRESSUREFROMTHEBOILER
Rapid water flow could cause injury.
3. 2EMOVEHOSEAFTERDRAINING
4. 2EMOVENIPPLESANDVALVESUNLESSTHEYWILLREMAINFORUSEIN
the system piping.
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INSTALLRELIEFVALVEDISCHARGEPIPING&AILURETO
INSTALLTHEBOILERRELIEFVALVECOULDRESULTINSEVERE
personal injury, death or substantial property
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3 Prepare boiler continued