Williamson-Thermoflo FreeStyle 2 Series User manual

FreeStyle
®
Wall Mount Gas-Fired
Condensing Boilers
Combi & Heat Only Models
80/120/155 – Series 2
*Low Lead Content
Part number 550-142-950/0919
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 Combi or Heating Only models
*CSA - Low Lead Content only applies to the Combi model
Quick Start
Guide
Pages 73 & 74
Boiler Manual
s)NSTALLATION
s3TARTUP
s-AINTENANCE
s0ARTS

Part number 550-142-950/0919
2
FreeStyle® Series 2 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 Please read before proceeding .............3
2 Prepare boiler location ..................4
3 Prepare boiler .......................6
4 Converting boiler to propane .............10
5 Gas piping — sizing gas lines .............14
6 Venting/air piping — general ..............15
7 Commonwealth of Massachusetts installations . . . 18
8 Vent termination requirements.............19
9 Boiler room air openings................20
10 DIRECT VENT — Sidewall with separate pipes . . . 21
11 DIRECT VENT — Sidewall concentric ........23
12 DIRECT VENT — Vertical with separate pipes....25
13 DIRECT VENT — Vertical concentric .........27
14 DIRECT VENT — Vertical vent /sidewall air .....29
15 Concentric termination, typical (sidewall or vertical) . . 31
16 Vent and air piping and boiler connections .....32
17 Install water piping ..................35
Domestic Water Piping – Combi Boiler .........35
Recirculation (if used) ................37
18 Primary/Secondary System Piping ................39
System water piping methods ............39
Expansion Tank Location ..............39
Diaphragm- or bladder-type tank: ..........39
Closed-type expansion tank: ............41
Install relief valve ...................42
Zone Valve zoning – primary/secondary .......43
Circulator zoning – primary/secondary .......44
Circulator zoning – Multiple temperature zones with
primary/secondary ..................45
19 Multiple boiler installations ..............46
20 Install condensate line ................49
21 Gas piping .......................50
22 Field wiring.......................52
23 Wiring diagram — FS-80/120 Combi Ladder .........54
23 Wiring diagram — FS-80/120 Combi Schematic.......55
24 Wiring diagram — FS-80/120 Heating Only Ladder .....56
24 Wiring diagram — FS-80/120 Heating Only Schematic . . . 57
25 Wiring diagram — FS-155 Combi Ladder ...........58
25 Wiring diagram — FS-155 Combi Schematic ........59
26 Wiring diagram — FS-155 Heating Only Ladder .......60
26 Wiring diagram — FS- 155 Heating Only Schematic ....61
27 Controls and operation ................62
28 DHW Settings (Combi Only) ..............67
29 Standard Altitude ...................69
30 High Altitude ......................70
31 Startup — Quick Start Guide using default settings 73
32 Startup ..........................75
 ................78
 ............84
35 Annual startup and general maintenance ......85
36 Annual startup .....................86
37 Troubleshooting ....................89
38 Maintenance ......................111
39 Replacement parts ................. 120
40 Connections, Dimensions and Engineering Data . 132
41 Ratings ........................ 135
......... 136

Part number 550-142-950/0919 3
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.
7HENSERVICINGBOILER
s To avoid electric shock, disconnect all
ELECTRICAL SUPPLIES TO THE BOILER BEFORE
PERFORMINGMAINTENANCE
s To avoid severe burns, allow boiler to
COOLBEFOREPERFORMINGMAINTENANCE
s This boiler contains ceramic fiber and
lBERGLASSMATERIALS2EFERTOTHE7!2.-
).'ANDINSTRUCTIONSON page 25.
"OILEROPERATION
s $ONOT BLOCK mOW OFCOMBUSTIONOR
ventilation air to boiler.
s Should overheating occur or gas supply
FAILTOSHUTOFFDONOTTURNOFFORDISCON-
nect electrical supply to pump. Instead,
SHUTOFF THE GAS SUPPLY AT A LOCATION
external to the appliance.
#OMBUSTIONAIR
s $/./4INSTALLCOMBUSTIONAIRINTAKE
WHERETHEREISARISKOFCOMBUSTIONAIR
contamination.
#ARBONMONOXIDEDETECTOR
s !CARBON MONOXIDEDETECTORTHAT IS
wired on the same electrical circuit as
the boiler is strongly recommended.
352'%02/4%#4/2
s Provide surge protection in the boiler
power supply. This will reduce the pos-
SIBILITYOFDAMAGETOTHEBOILERCONTROL
*
In some locations, a carbon monoxide
detector is required by the law.
"OILERWATER
s The FreeStyleHEATEXCHANGERISMADEOF
stainless steel, and requires that system
water chemistry be within the limits in
this manual. Use Sentinel X100 inhibitor
in the boiler. !$$)4)/.!,#(%-)#!,
42%!4-%.4 -!9"%.%#%33!29. See
page 75FORDETAILS
s Thoroughly flush the system (BEFORE
connecting boiler) to remove sediment.
4HEHIGHEFlCIENCYHEATEXCHANGERCAN
be damaged by build-up or corrosion
due to sediment.
s 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.
s #ONTINUALFRESHMAKEUPWATERWILL
REDUCEBOILER LIFE-INERAL BUILDUP IN
EATEXCHANGERREDUCESHEATTRANSFER
overheats the aluminum heat exchanger,
ANDCAUSESFAILURE!DDITIONOFOXYGEN
carried in by make-up water can cause
internal corrosion. Leaks in boiler or
piping must be repaired at once to
prevent make-up water. Use this boiler
/.,9INACLOSEDLOOPSYSTEM
s Do not add cold water to a hot boiler.
Thermal shock can cause heat exchanger
to crack.
&REEZEPROTECTIONmUIDS
s .%6%2USE AUTOMOTIVEOR STANDARD
GLYCOLANTIFREEZE5SEONLYFREEZEPROTEC-
TIONmUIDSMADEFORHYDRONICSYSTEMS
Follow all guidelines given by the anti-
FREEZEMANUFACTURER4HOROUGHLYCLEAN
and flush any replacement boiler system
THATHASUSEDGLYCOLBEFOREINSTALLINGTHE
new boiler Use only the products listed
BY7ILLIAMSON4HERMOmOFORUSEWITH
this boiler. See page 121FORDETAILS
Frozen Water Damage
Hazard
Residences or buildings that are unat-
tended in severely cold weather, boiler
SYSTEMCOMPONENTSFAILURESPOWEROUT-
AGESOROTHERELECTRICAL SYSTEM FAILURES
COULDRESULTINFROZENPLUMBINGANDWATER
DAMAGEINAMATTEROF HOURS&ORYOUR
protection, take preventative actions such
as having a security system installed that
operates during power outages, senses low
TEMPERATUREANDINITIATESANEFFECTIVEAC-
tion. Consult with your boiler contractor
or a home security agency.
If any part of a boiler, burner or its controls has
been sprayed with or submerged under water,
either partially or fully, DO NOT attempt to op-
erate the boiler until the boiler has been either
replaced or completely repaired, inspected, and
you are sure that the boiler and all components
are in good condition and fully reliable.
Otherwise, by operating this boiler, you will
cause a fire or explosion hazard, and an electrical
shock hazard, leading to serious injury, death, or
substantial property damage. See the instructions
at right.
Saltwater Damage — 4HEEXPOSUREOFBOILER COMPONENTSTO
SALTWATERCANHAVEBOTHIMMEDIATEANDLONGTERMEFFECTS7HILE
THEIMMEDIATEEFFECTSOFSALTWATERDAMAGEARESIMILARTOTHOSEOF
FRESHWATERSHORTINGOUT OF ELECTRICALCOMPONENTS WASHINGOUT
OFCRITICALLUBRICANTSETCTHE SALT AND OTHER CONTAMINANTS LEFT
BEHINDCANLEADTOLONGERTERMISSUESAFTERTHEWATERISGONEDUETO
THECONDUCTIVEANDCORROSIVENATUREOFTHESALTRESIDUE4HEREFORE
Williamson-Thermoflo equipment contaminated with saltwater
or polluted water will no longer be covered under warranty and
should be replaced.
%LECTRICAL $AMAGE)FANYELECTRICAL COMPONENT or wiring
came into contact with water, or was suspected to have come into
contact with water, replace the boiler with a new Williamson-
Thermoflo boiler.
Commonwealth of
Massachusetts
7HEN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PREVENTERDEVICESHALLBEUSED
s Sidewall vent air installations — see instruction on page 18.
)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QUALIlED
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.
Failure to comply with the above could result in severe
personal injury, death or substantial property damage.
Write in the Consumer Protection (CP) number in
the space provided on the Installation certificate on
page 136IFNOTALREADYSHOWN
When calling or writing about the boiler— Please
HAVETHEBOILERMODELNUMBERFROMTHEBOILERRATING
LABELANDTHE#0NUMBERFROMTHEBOILERJACKET
Consider piping and installation when determining
boiler location.
 !NYCLAIMSFORDAMAGEORSHORTAGE IN SHIPMENT
must be filed immediately against the transportation
company by the consignee.
1 Please read before proceeding

Part number 550-142-950/0919
4
FreeStyle® Series 2 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!LATESTEDITION
s .ATIONAL%LECTRICAL#ODE!.3).&0!nLATESTEDITION
s Where required by the authority having jurisdiction, the instal-
LATIONMUSTCONFORMTOTHE3TANDARDFOR#ONTROLSAND3AFETY
$EVICESFOR!UTOMATICALLY&IRED"OILERS!.3)!3-%#3$
#ERTIlCATION
The FreeStyle®BOILERGASMANIFOLDANDCONTROLSmet
SAFELIGHTINGANDOTHERPERFORMANCECRITERIAWHEN
BOILERUNDERWENTTESTSSPECIlEDIN!.3):
latest edition.
Flooring
1. The boiler must not be installed on carpeting.
$ONOTINSTALLBOILERONCARPETINGEVENIFFOUNDA-
tion is used. Fire can result, causing severe personal
injury, death or substantial property damage.
"EFORELOCATINGTHEBOILER
1. 7ALL CONSTRUCTION -AKESURETHE WALL CONSTRUCTION IS
SUITABLETOCARRYTHEWEIGHTOFTHEBOILERANDCOMPONENTS
See page 7FORINSTRUCTIONS
2. 4HEBOILERISSUITABLEFOR).$//2INSTALLATION only.
3. #HECKFORNEARBYCONNECTIONTO
s System water piping
s 6ENTINGCONNECTIONS
s 'ASSUPPLYPIPING
s %LECTRICAL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"%&/2%CONNECTINGTHENEWBOILER3EEpage 75.
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 %NSURE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
3%26)#%CLEARANCESSHOWNINFigure 1, page 5.
2. &ORSPACESTHAT$/./4SUPPLYTHEMINIMUMSERVICECLEAR-
ances, provide two openings as shown in Figure 1, page 5.
%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
Follow the sizing requirements shown in Figure 23, page 20.
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!.3):
$IRECT6ENTPRESSURIZEDVENTLIKELYTOCONDENSEINTHEVENT3EE
instructions beginning on page 15.
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 6 when considering vent/air
termination.
3. 6ENTANDAIRMUSTTERMINATENEARONEANOTHERUNLESSOTHERWISE
SPECIlEDINTHISMANUAL6ENT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. "E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 15.

Figure 1 REQUIREDMINIMUMCLEARANCES
(ALLDIMENSIONSAREININCHES)
Part number 550-142-950/0919 5
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
2 Prepare boiler location continued
Provide clearances from
combustible materials — REQUIRED
1. See Figure 1FOR 2%15)2%$MINIMUMCLEARANCES!,,
installation must provide at least these minimums.
2. (OTWATERPIPESATLEASTvFROMCOMBUSTIBLEMATERIALS
3. 6ENT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 1.
Provide clearances for service
access — RECOMMENDED
1. See Figure 1,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 1ALLOWSFORTHEINSTALLATIONOFPIPINGAS
shown in Figure 5, page 9, plus a union, close nipple and
elbow.
Clearances A Provide combustion air/ventilation openings per Figure 23,page 20
or as otherwise directed in this manual or by applicable codes.
If the installation does not provide the minimum clearances,
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.
 !$$)4)/.!,SERVICECLEARANCEMAYBE
needed, depending on how piping is routed
to the boiler.
A Provide combustion air/ventilation openings per Figure 23, page 20 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 1.
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 550-142-950/0919
6
FreeStyle® Series 2 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 fixture 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 locations
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.
 %NSURE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 2 !DDITIONOFRUBBERBUMPERFOR WALLMOUNTING
2 inches
14 inches-center to center of rubber
Lag bolt mounting locations
Part number 550-142-950/0919 7
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
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 3, 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.
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
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 4.
3 Prepare boiler continued
Wall-mounting requirements
$/./4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
FreeStyle®155: 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"OILER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 2.
2. $/./4DRILLHOLESTOMOUNTTHERUBBERBUMPERS
Figure 3 7ALLMOUNTBRACKET
Figure 4 7ALLMOUNTBRACKETTABSBENDOVERBOILERTO
SECUREBOILERINPLACE
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.)
6. Position the wall-mount bracket on the wall. Insert and
LOOSELYTIGHTENTHETWOLAGSCREWSORTOGGLEBOLTSFOR
metal studs).
Bend tabs after installation

Part number 550-142-950/0919
8
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
Hydrostatic pressure test
 $/./4INSTALLARELIEFVALVEWITHAPRESSURE
HIGHER THAN  03)'4HIS IS THE MAXIMUM
ALLOWABLE RELIEF VALVE SETTING FOR THE 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 5, page 9. !PPLY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 6, page 9.
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1” .04ON&31-1/4”.04
on FS-155).
b. Two close nipples (1”.04ON&31-1/4”.04ON
FS-155).
c. Ðv.04PIPEPLUG
d. Pressure/temperature gauge.
e. Ðv.04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 5, page 9,FORUSEWITHTHEFOLLOWINGINSTRUCTIONS
2. #,/3%THEBOILERDRAINVALVEITEM#ONNECT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. #,/3%ISOLATIONVALVEITEM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)'
#,/3%THEBOILERDRAINVALVEITEM
9. (OLDATTESTPRESSUREFORMINUTES
$ONOTLEAVEBOILERUNATTENDED!COLDWATERlLL
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.
5. 2EMOVEPLUGANDINSTALLRELIEFVALVEASSPECIlEDINTHEFOL-
LOWING7!2.).'
2EMOVEPLUGFROMRELIEFVALVESTREETELBOW)NSTALL
THERELIEFVALVEINTHEÐvSTREET3EEpage 42 to install
RELIEFVALVEDISCHARGEPIPING&AILURETOINSTALLTHE
BOILERRELIEFVALVECOULDRESULTINSEVEREPERSONAL
injury, death or substantial property damage.
3 Prepare boiler continued

Figure 5 )NSTALLPIPElTTINGSFORRELIEFVALVEANDPRESSURE
TEMPERATUREGAUGE$/./4MOUNTRELIEF
VALVEUNTIL!&4%2HYDROSTATICTESTING(see
legend below) (Combi boiler shown)
Figure 6 )NSTALLPIPINGCOMPONENTSREQUIREDFOR
HYDROSTATICTESTsee legend below)
Part number 550-142-950/0919 9
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
1. Boiler supply (outlet) connection, (male, 1”NPT ON&3v.04ON&3
2. Boiler return (inlet) connection, (male, 1” NPT ON&3v.04ON&3
Recommend Near Boiler Piping to be 1-1/4”NPT or larger FORFS-155. Bushing 1”x 1-1/4”NPT at Supply (outlet) and Return (inlet) not
shown. (field supplied by installer)
3. Boiler relief valve,shipped loose with boiler — $/./4MOUNTRELIEFVALVEUNTIL!&4%2HYDROSTATICTESTING.
3a. 4%-0/2!2),9/.,9 Insert a ¾”NPT plug in the relief valve tapping of the reducing tee.This MUST BE REMOVED
after the test and the relief valve mounted here.
4. Pressure/temperature gauge,
(field supplied) by installer
5a. R educing tee, NPT, 1” x 1”x ¼”on FS-80/120, NPT, 1-¼”x 1-¼”x ¼” on FS-155.
5b. Tee,NPT, 1” x 1”x ¾” on FS-80/120, NPT,1-¼”x 1-¼” x ¾” on FS-155.
6. Nipple, NPT 1”x close on FS-80/120, NPT, 1-¼” x close on FS-155,(field supplied) by installer.
7. Nipple, NPT 1”x close on FS-80/120, NPT, 1-¼” x close on FS-155,(field supplied) by installer.
8. Isolation valve on supply connection, (field supplied) by installer (1”NPT on FS-80/120, 1-¼v.04ON&3
9. Isolation valve on return connection,(field supplied) by installer (1”NPT on FS-80/120, 1-¼v.04ON&3
10. ¾”NPT boiler drain valve, (field supplied) by installer — after hydrostatic testing, move drain valve to lowest point on the return piping
if not already there.
3 Prepare boiler continued
2
1
"OILER2ETURN
INLET
"OILER3UPPLY
OUTLET
310

Part number 550-142-950/0919
10
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
4 Converting boiler to propane
Prepare boiler for propane (if required)
FreeStyle®80/120/155
Propane operation
ALL FreeStyle®BOILERSMUSTBECON-
VERTEDFORPROPANEOPERATION.
Converting an existing natural gas-fired
BOILERFORPROPANE — For a boiler already
INSTALLEDYOUMUSTTURNOFFGASSUPPLYTURNOFF
POWERANDALLOWBOILERTOCOOLBEFOREPROCEED-
ING9OUMUSTALSOCOMPLETELYTESTTHEBOILERAFTER
CONVERSIONTOVERIFYPERFORMANCEANDSTARTUP
THEBOILERFOLLOWINGINSTRUCTIONSBEGINNINGON
page 79OFTHISMANUAL
Verify Conversion kit—See Figure 7.
LP gas venturi will have a black label and will be
clearly labeled “LPG”.
 .ATURALGASVENTURIWILLHAVEAWHITELABELAND
will be clearly labeled “NG”.
Failure to comply could result in severe personal
injury, death or substantial property damage.
Figure 7 .ATURALAND,IQUElED0ETROLEUM0ROPANEGAS
CONVERSIONKITS
Boiler Model +IT0ART.UMBER
&3.' 640-000-022WT
&3,0 640-000-024WT
&3.' 640-000-023WT
&3,0 640-000-025WT
&3.' 640-000-082WT
&3,0 640-000-133WT
This conversion kit shall be installed by a qualified
service agency in accordance with the
manufacturer’s instructions and all applicable codes
and requirements of the authority having jurisdiction.
If the information in these instructions is not followed
exactly, a fire, an explosion or production of carbon
monoxide may result causing property damage,
personal injury or loss of life. The qualified service
agency is responsible for the proper installation of this
kit. The installation is not proper and complete until
the operation of the converted appliance is checked as
specified in the manufacturer’s instructions supplied
with the kit.
s Follow all instructions in proper order.
s $ONOTTAMPERWITH VENTURI $/ ./4CHANGEOR MODIFY
venturi in any way.
s Do not leave an uninstalled venturi in the building.
s #AUTIONTHEGASSUPPLYSHALLBESHUTOFFPRIORTODISCONNECTING
THEELECTRICALPOWERBEFOREPROCEEDINGWITHTHECONVERSION
Label all wires prior to disconnection when servic-
ing controls.Wiring errors can cause improper and
dangerous operation.
&3.'P/N 640-000-022WT LP to Natural Gas Conversion Kit contents:
36602390 Venturi - Natural Gas 10.6m 1
35105080 Gasket Nitrile Rubber 167 x 63.5X3.53 NBR 1
3541F210 Label Gas Conversion 1
3541G190 Label FS-80 Rating Plate Conversion NG 1
550-142-855 Instructions Conversion LP to Natural Gas 1
&3.'P/N 640-000-023WT LP to Natural Gas Conversion Kit contents:
36602400 Venturi - Natural Gas 12.6m 1
35105080 Gasket Nitrile Rubber 167 x 63.5X3.53 NBR 1
3541F210 Label Gas Conversion 1
3541G480 Label FS-120 Rating Plate Conversion NG 1
550-142-855 Instructions Conversion LP to Natural Gas 1
&3,0P/N 640-000-024WT NG to Propane Gas Conversion Kit contents:
36602430 Venturi - 10.6 GPL 1
35105080 Gasket Nitrile Rubber 167 x 63.5X3.53 NBR 1
3541F210 Label Gas Conversion 1
3541G190 Label FS-80 Rating Plate Conversion LP 1
550-142-854 Instructions Conversion Nat to LP Gas 1
&3,0P/N 640-000-025WT NG to Propane Gas Conversion Kit contents:
36602450 Venturi - 12.6 GPL 1
35105080 Gasket Nitrile Rubber 167 x 63.5X3.53 NBR 1
3541F210 Label Gas Conversion 1
3541G200 Label FS-120 Rating Plate Conversion LP 1
550-142-854 Instructions Conversion Nat to LP Gas 1
&3,0P/N 640-000-133WT NG to Propane Gas Conversion Kit contents:
36602880 Venturi - 1
35105080 Gasket Nitrile Rubber 167 x 63.5X3.53 NBR 1
3541F210 Label Gas Conversion 1
3541G200 Label FS-155 Rating Plate Conversion LP 1
550-142-854 Instructions Conversion Nat to LP Gas 1
&3.'P/N 640-000-082WT LP to Natural Gas Conversion Kit contents:
36602870 Venturi - Natural Gas 16.6m 1
35105080 Gasket Nitrile Rubber 167 x 63.5X3.53 NBR 1
3541F210 Label Gas Conversion 1
3541G480 Label FS-155 Rating Plate Conversion NG 1
550-142-855 Instructions Conversion LP to Natural Gas 1
.ATURALTO,0#ONVERSION+IT0ART.UMBERS
,0TO.ATURAL#ONVERSION+IT0ART.UMBERS

Part number 550-142-950/0919 11
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
0IPESIZINGFORPROPANEGAS
1. Contact propane gas supplier to size piping, tank and install
ALOCKUPGASPRESSUREREGULATORORTOVERIFYSIZEAND
CONDITIONOFEXISTINGPIPINGANDEQUIPMENT
.ATURALAND0ROPANESUPPLYPRESSURE
requirements
!DJUSTPROPANESUPPLYREGULATORPROVIDEDBYGASSUPPLIERFORv
w.c. maximum pressure.
For natural gas or propane, the pressure required at gas valve inlet
PRESSUREPORTVERIFYMINIMUMGASPRESSUREWHENALLGASAPPLI-
ances are in operation):
a. -AXIMUMvWCWITHNOmOWLOCKUPORWITHBOILERON
b. -INIMUMGASPRESSUREWITHGASmOWINGVERIFYDURINGBOILER
startup, while boiler is at high fire)
— FreeStyle®80: 3.5” w.c.;
— FreeStyle®120: 3.5” w.c.;
— FreeStyle®155: 3.5” w.c.
c. .OMINALGASPRESSUREvWC
2. Install 100% lockup gas pressure regulator in supply
LINEIFINLET PRESSURECANEXCEEDvWCATANYTIME
!DJUSTLOCKUPREGULATORFORvWCMAXIMUM
3. !FTERCONNECTING PROPANEGASLINETOBOILERAND "%&/2%
OPERATINGCHECK GAS PRESSURE)F GAS PRESSUREIS NOT IN THE
range above, close manual gas valve and contact gas supplier
TOCORRECTTHEPROBLEMBEFOREATTEMPTINGTOSTARTOROPERATE
the boiler.
Installing venturi —
)FBOILERISALREADYINSTALLED9OUMUSTTURNOFF
electrical supply to the boiler and close the external
MANUALGASSHUTOFFVALVETOISOLATETHEBOILERDURING
CONVERSION!LLOWTHEBOILERTOCOOLIFITHASBEEN
operating.
&OLLOWINGCONVERSIONOFANINSTALLEDBOILERFOLLOW
all instructions in this manual to start up the boiler
ANDVERIFYOPERATION OFTHEBOILERANDALLSYSTEM
components.
6ERIFYPROPERVENTURIFORGASTYPE
The venturi(s) provided with the kit(s) are permanently marked
on labels to indicate gas type “NGv  .ATURALGASORhLPGvFOR
Liquefied petroleum (propane) gas and supplier part number.
See Figure 7, page 10FORKITCONTENTS
4 Converting boiler to propane continued
,%'%.$FORFigure 11
1Control module 2'ASVALVE
Figure 8 .ATURALGASVENTURILABELINFORMATION
Figure 9,IQUElED0ETROLEUMPROPANEGASVENTURILABEL
INFORMATION
Figure 10 2EMOVINGFRONTPANEL
Figure 11-OVINGCONTROLMODULEFORACCESSTOGASVALVE
&RONTPANELREMOVAL
1. Remove two (2) ASCREWSONTHEBOTTOMmANGEOFFRONTPANEL
OUTANDLIFTUPTOREMOVETHEFRONTPANEL
2. Remove the one (1) screw holding control module in place
Figure 11, rotate the control module.
1
2
A

Part number 550-142-950/0919
12
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
3. ,OOSENTHEBOTTOMSWIVELNUTOFGASPIPEANDUNSCREWTHE
TOPSWIVELNUTh!vFigure 12,)TEMFROMTHEGASVALVEVENTURI
Figure 12, Item 6.
4 Converting boiler to propane continued
Figure 12 ,OOSENlTTINGSOFGASPIPE#ONTROLMODULE
REMOVEDFORCLARITY
,%'%.$FORFigures 13, 14, 15. 16 and 17
1Control panel (page 13)
2'ASVALVE
3'ASPIPE
4Washer
5Hex head screws
6'ASVALVEVENTURI
7“O” Ring
8"LOWER
A
3
6
2
4
3
5
8
A
6
3
4
5
Figure 13 'ASVALVEVENTURIREPLACEMENTFORPROPANE
CONVERSION
Figure 14)NSUREh/vRINGISINPLACE
Figure 15.EW,0VENTURIINSTALLEDTOBLOWER
4. Remove three (3) Hex head screws holding the venturi, Item
5 in place, remove venturi, replace with new propane venturi
FROMKIT6ERIFY THE VENTURILABEL INFORMATIONMATCHES THE
boiler size FS-80/120/155. (Propane venturi has black label),
ensure Item 7, venturi “O” ring is in place (see Figure 14), re-
insert three (3) Hex head screws to hold new venturi, tighten
to hold securely in place.
5. Reassemble gas pipe and new washer to the venturi fitting,
RECONNECTNUTh!vANDGASPIPEh)TEMvTOVENTURIAND
CHECKTHESEALOFTHECONNECTION
)NSPECTTHE GAS PIPE FITTING CONNECTIONS ON
the gas valve and new venturi (Item 3, Fig-
ure 12, page 12CHECKTHESEALOFTHE CONNEC-
tions. Failure to comply will cause a gas leak,
resulting in severe personal injury or death.
7

Part number 550-142-950/0919 13
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
4 Converting boiler to propane continued
4HEJACKETDOORMUSTBEINPLACEDURING
OPERATION$/./4OPERATETHEBOILERWITH
THEJACKETDOORREMOVEDEXCEPTFORINSPECTION
and testing as directed in this manual.
Figure 16 'ASPIPEREASSEMBLEDTO,0VENTURIlTTING
A
3
5
Figure 17 )NSTALLERCONVERSIONLABEL
 $ONOTCHECKFORGASLEAKSWITHANOPENmAMEUSE
BUBBLETEST&AILURETOUSEBUBBLETESTORCHECKFOR
gas leaks can cause severe personal injury, death or
substantial property damage.
6. Reinstall control module, reinstall screw to hold control
module securely in place
7. Reinstall jacket door, and secure with two (2) screws.
Mandatory control changes for fuel con-
version - Perform at start-up final checks
8. Adjust parameter for the type of gas:
a. Put the boiler in standby mode.
b. Press the DHW buttons details 1 and 2 - Figure 80, page 62
FORSECONDSTHEDISPLAYSHOWShBhmASHING
c. Press the DHW buttons Figure 80, page 62 details 1 and 2
TOSETPARAMETERFORUSEWITHNATURALGASOR  
FORUSEWITH,0
d. Press the Heating (+) button to scroll to Parameter “b04”.
 E0RESS$(7TOREDUCETHE-AXIMUM"LOWER 
see Figure 128, page 101.
 F0RESSTHEBUTTONTOSCROLLTO0ARAMETERhBv
g. Repeat Step “e” above according to your boiler size.
h. Press the Heating (+) button to scroll to Parameter
“b06”.
 I0RESS$(7TOREDUCETHE-INIMUM&AN3PEED,
see Figure 128, page 101:
j. Press the DHW buttons details 1 and 2 -
Figure 80, page 62FORSECONDS
k. The boiler will return to standby mode.
9. 4URNONGASBYOPENINGGASVALVECHECKFORLEAKSANDCONTINUE
boiler start up and adjustments, staring on page 82.
10. 4ESTIGNITIONSYSTEMSAFETYSHUTOFFSEE page 83.
11. )N53!)NPUTRATESAREDERATEDFOREACHFTABOVESEA
LEVELBEYONDFTINACCORDANCEWITH.ATIONAL&UEL'AS
#ODE!.3):.&0! - latest edition.
12. Using a combustion analyzer insert probe into the flue test
point, check that the CO2content in the exhaust,with the boil-
er operating at max. and min.firing rate, matches that given in
the technical data Figure 107, page 82 or Figure 110, page 83,
FORTHECORRESPONDINGTYPEOFGAS
$/ ./4 !44%-044/ -%!352%6!,6%
/54,%4 02%3352% The valve could be
DAMAGEDBYMANOMETER FLUID CONTAMINATION
Failure to comply could result in severe personal
injury, death or substantial property damage.
Perform Boiler Manual start-up
 &OLLOWALLINSTRUCTIONSIN"OILER-ANUALTOSTARTUP
THEBOILERAFTERCONVERTINGFORPROPANE"ECAUSETHE
boiler has been changed, you must verify correct
operation, including checking combustion with
test instruments both at high fire and low fire as
described in the Boiler Manual, pages 81, 82 & 83
#HECKTHECORRECTIGNITIONSEQUENCEOFTHEBOILER
AFTERTHECONVERSIONASINPAGE90.
Failure to comply could result in severe personal
injury, death or substantial property damage.
Reinstall boiler jacket front door
2EPLACEBOILERJACKETFRONTDOORAFTERSERVICING
4HEBOILERFRONTDOORMUSTBESECURELYFASTENEDTO
THEBOILERFRAME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 keep the door securely
FASTENEDCOULDRESULTINSEVEREPERSONALINJURYOR
death.
Apply installer conversion label
1. #ONVERTINGTOPROPANElRING!FTERINSTALLATIONISCOMPLETE
ATTACHTHE PROPANECONVERSIONLABEL FROMKITNEXTTOTHE
boiler rating label.
 #ONTRACTORINSTALLERIS RESPONSIBLEFORCOMPLETINGTHE IN-
FORMATIONREQUIREDONLABELPROVIDEDINKITANDATTACHING
installer conversion label next to the boiler rating label.

Part number 550-142-950/0919
14
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
5 Gas piping — sizing gas lines
 "OILERGASCONNECTIONISv.04FORBOILERS
 ANDÐv .04 FOR  BOILERS3IZE GAS LINES LARGE
enough to provide gas to all connected appliances.
Natural Gas:
0IPESIZINGFORNATURALGAS
1. 3IZEGAS PIPINGFROMMETEROUTLET TOENTRANCEOF BOILERIN
accordance with Figure 18 and Figure 19.
2. 5SETOTALINPUTOFALLCONNECTEDAPPLIANCES$IVIDETOTALINPUT
IN"TUHBYTOOBTAINCUBICFEETPERHOUROFNATURALGAS
a. Pipe lengths in Figure 18AREEQUIVALENTLENGTHOFSTRAIGHT
pipe. Convert pipe fittings to equivalent lengths using
DATAFROMFigure 19.
b. Figure 18ISONLYFORNATURALGASWITHSPECIlCGRAVITY
with a pressure drop through the gas piping as listed in
the table.
.ATURALGASSUPPLYPRESSURE
1. Pressure required at gas valve inlet pressure port:
a. -AXIMUMvMMWCWITHNOmOWLOCKUP
b. -INIMUMGASPRESSUREWITHGASmOWINGVERIFYDURING
boiler startup, while boiler is at high fire):
FreeStyle®80: 3.5” w.c.
FreeStyle®120: 3.5” w.c.
FreeStyle®155: 3.5” w.c.
.OMINALGASPRESSUREvWC
2. )NSTALLLOCKUPGASPRESSUREREGULATORINSUPPLYLINEIF
INLETPRESSURECANEXCEEDvWCATANYTIME!DJUSTLOCKUP
REGULATORFORvWCMAXIMUM
Propane Gas:
 9OU MUST FOLLOWTHEINSTRUCTIONSBEGINNINGON
page 10, to operate the boiler on propane. Failure
to comply could result in severe personal injury,
death or substantial property damage.
0IPESIZINGFORPROPANEGAS
1. Contact gas supplier to size pipes, tanks and 100% lockup
gas pressure regulator.
0ROPANESUPPLYPRESSURE
1. !DJUSTPROPANESUPPLYREGULATORPROVIDEDBYGASSUPPLIERFOR
13” w.c. maximum pressure.
2. Pressure required at gas valve inlet pressure port:
a. -AXIMUMvWCWITHNOmOWLOCKUP
b. -INIMUMGASPRESSUREWITHGASmOWINGVERIFYDURING
boiler startup, while boiler is at high fire):
FreeStyle®80: 3.5” w.c.
FreeStyle®120: 3.5” w.c.
FreeStyle®155: 3.5” w.c.
.OMINALGASPRESSUREvWC
Figure 18 0IPECAPACITYFORSPECIlCGRAVITYNATURAL
GASPIPELENGTHISINEQUIVALENTFEET
Gas
PIPE
total
LENGTH
feet
#APACITY
#UBICFEETPERHOURNATURALGASSPECIlCGRAVITY
'ASPRESSUREvWCORLESS
0RESSUREDROPINCHESWC
½” ¾” 1” 1¼” 1½” 2” 2½”
10 132 278 520 1050 1600 3050 4800
20 92 190 350 730 1100 2100 3300
30 73 152 285 590 890 1650 2700
40 NA 130 245 500 760 1450 2300
50 NA 115 215 440 670 1270 2000
75 NA 105 175 360 545 1020 1650
100 NA 96 150 305 460 870 1400
150 NA 90 120 250 380 710 1130
Figure 19 %QUIVALENTLENGTHSOFSTRAIGHTPIPEFORTYPICAL
GASLINElTTINGS
0IPESIZE
INCHES
%QUIVALENTLENGTHFEET
90° Elbow Tee
short
radius
long
radius
line
mOW
BRANCH
mOW
½3.6 2.2 1.7 4.2
¾4.4 2.3 2.4 5.3
15.2 2.7 3.2 6.6
1¼ 6.6 3.2 4.6 8.7
1½ 7.4 3.4 5.6 9.9
28.5 3.6 7.7 12.0
2½ 9.3 4.0 9.3 13.0

Part number 550-142-950/0919 15
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
6 Venting/air piping — general
!NYIMPROPEROPERATIONOFCOMMONVENTINGSYSTEMSHOULD
BECORRECTEDSOTHEINSTALLATIONCONFORMSWITHTHE.ATIONAL
&UEL'AS#ODE!.3):LATESTEDITION#ORRECTBYRE
sizing to approach the minimum size as determined using the
APPROPRIATETABLESIN0ARTOFTHATCODE
Do not install the FreeStyle®boiler into a com-
mon vent with any other appliance. This will
CAUSEmUEGASSPILLAGEORAPPLIANCEMALFUNCTION
resulting in possible severe personal injury, death
or substantial property damage.
 %XISTINGCOMMONVENTSYSTEMSMAYBETOOLARGE
FORTHEAPPLIANCESREMAININGCONNECTEDAFTERTHE
existing boiler is removed.
 &AILURETOFOLLOWALL INSTRUCTIONS CAN RESULT IN
flue gas spillage and carbon monoxide emissions,
causing severe personal injury or death.
When removing a boiler from an
existing common vent system
4HEBOILERCANNOTBECOMMONVENTEDWITHANYOTHERAP-
PLIANCE. When an existing boiler is replaced with a FreeStyle®
BOILERTHEBOILER#!../4USETHEexisting common vent. The
boiler requires its own vent and air piping, as specified in this
MANUAL4HISMAYCAUSEAPROBLEMFORTHEAPPLIANCESTHATREMAIN
on the old common vent, because the vent may be too large. The
FOLLOWINGTESTISINTENDEDTOCHECKFORPROPEROPERATIONOFTHE
appliances remaining on the old common vent system.
6ENTSYSTEMVERIlCATION
0ERFORMTHETESTSEQUENCEBELOWFOREACH appliance remaining
on the original common vent system. Operate each appliance
INDIVIDUALLYWITHOTHERAPPLIANCESTURNEDOFF4HISPROCEDURE
will test whether the common vent system can properly vent
each appliance.
Existing vent test procedure
(The following is intended to test whether the appliances
remaining on an existing vent system will operate
satisfactorily.)
1. Seal any unused openings in the common venting system.
2. 6ISUALLYINSPECTTHEVENTINGSYSTEMFORPROPERSIZEANDHORI-
zontal pitch and determine there is no blockage or restriction,
leakage, corrosion or other deficiencies which could cause an
UNSAFECONDITION
3. 4EST VENT SYSTEM)NSOFARAS IS PRACTICALCLOSE ALL BUILD-
ing doors and windows and all doors between the space in
which the appliances remaining connected to the common
VENTINGSYSTEMARELOCATEDANDOTHERSPACESOFTHEBUILDING
Turn on clothes dryers and any appliance not connected to
THECOMMONVENTINGSYSTEM4URNONANYEXHAUSTFANSSUCH
as range hoods and bathroom exhausts, so they will operate
ATMAXIMUMSPEED$ONOTOPERATEASUMMEREXHAUSTFAN
Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow
THEOPERATINGINSTRUCTIONS!DJUSTTHERMOSTATSOAPPLI-
ance will operate continuously.
5. 4EST FOR SPILLAGEATDRAFT HOOD RELIEFOPENING AFTER 
MINUTESOFMAINBURNEROPERATION5SETHEmAMEOFA
MATCHORCANDLEORSMOKEFROMACIGARETTECIGARORPIPE
6. !FTERITHASBEENDETERMINEDTHATEACHAPPLIANCEREMAIN-
ing connected to the common venting system properly
vents when tested as outlined herein, return doors, win-
DOWSEXHAUSTFANSlREPLACEDAMPERSANDANYOTHERGAS
BURNINGAPPLIANCETOTHEIRPREVIOUSCONDITIONSOFUSE

Figure 20Venting and air piping — DIRECT VENT ONLY/04)/.3AND0)0).',)-)43
The table below lists the acceptable vent/air pipe terminations described in this manual. Follow all instructions provided to install the
vent/air system. ./43(/7. below, but also approved, are the polypropylene piping and terminations listed in Figure 21, page 17.
&ORTHESEAPPLICATIONSUSE/.,9THEMANUFACTURERSPARTSLISTEDANDFOLLOWALLINSTRUCTIONSPROVIDEDBYTHEPIPEMANUFACTURER
Part number 550-142-950/0919
16
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
6 Venting/air piping — general continued
FreeStyle®Model
Maximum vent and air pipe length =
100 feet for all applications
(Minimum length for all applications is 2 feet equivalent plus termination)
!LLAPPLICATIONSINCLUDEALLOWANCEFORTHETERMINATIONlTTINGSPLUSONEELBOWINAIRPIPINGANDONEELBOWINVENTPIPING
USE
SWEEP
ELBOWS
ONLY
See Figure 21, page 17 for material specifications | See Figure 164, page 121 for part/kit numbers
Vent and air pipe sizes:
Maximum vent lengths apply for 3”vent and air pipe.
Boilers will derate as vent/air pipe length increases — * see Rating data on Figure 178, page 135 for derate amounts.
SIDEWALL termination VERTICAL termination
Separate pipes
[Note 1]
PVC or PP Concentric
[Note 1]
Separate pipes
[Note 1]
PVC or PP Concentric
[Note 1]
Vertical vent,
Side Air [Note 1]
See page 21 See page 23 See page 25 See page 27 See page 29
Size,
inches
Materials
Fig. 21, page 19
Size,
inches
Materials
Fig. 21, page 19
Size,
inches
Materials
Fig. 21, page 19
Size,
inches
Materials
Fig. 21, page 19
Size,
inches
Materials
Fig. 21, page 19
80
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
120
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
2
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
155
2
CPVC, PP, SS
2
--------
2
CPVC, PP, SS
2
--------
2
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
3
PVC/PVC-DWV
CPVC, PP, SS
!LLELBOWSINVENTANDAIRPIPINGMUSTBESWEEPELBOWS/.,9$/./4USESHORTRADIUSELBOWS
Equivalent feet for elbows (USE SWEEP ELBOWS ONLY) —
deduct from max equivalent length of piping (does not apply to termination fittings).
tGFFUQFSGPSFBDIBEEJUJPOBM¡TXFFQFMCPXPS¡FMCPX *GQJQJOHDPOUBJOTNPSFUIBOFMCPXJOBJSPSWFOUQJQJOHPUIFSUIBOUFSNJOBUJPOmUUJOHT
Note 1:
"#4NBZCFVTFEGPSJOUBLFBJS
.BUFSJBMBCCSFWJBUJPOT11QPMZQSPQZMFOF44"-$TUBJOMFTTTUFFM
If using stainless pipe, provide adapters for terminations, if required.
*1&9w17$DPODFOUSJDWFOULJUTDBOCFVTFEXJUITUBOEBSE17$QJQFmUUJOHTBOEDFNFOU"/4*"45.%FYDFQUJG6-$4DPNQMJBODF
JTSFRVJSFE'PS6-$4DPNQMJBODFBMMQJQFmUUJOHTBOEDFNFOUNVTUCF*1&94ZTUFN*GVTJOH*1&9LJUTVTFPOMZ*1&9QSPEVDUDPEF
GPSwWFOUJOH

Figure 21Vent and air piping materials5SEONLYTHEMATERIALSLISTEDBELOWENSURINGTHATALLMATERIALSMEETLOCAL
CODESsee Figure 164, page 121 for part/kit numbers)
Part number 550-142-950/0919 17
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
6 Venting/air piping — general continued
ALL vent and air pipes require a BIRD SCREEN at each termination. Most kits do not include
the bird screens. Purchase bird screens separately from Williamson-Thermoflo or vent kit sup-
plier if not included. [Note — bird screening is integral to the 3” PVC W- T sidewall vent cap,
available for purchase from Williamson-Thermoflo . No additional screening is required.]
USE SWEEP ELBOWS FOR ALL VENT AND AIR PIPING — DO NOT use short
radius elbows for vent or air piping. Boiler performance could be affected.
)TEM Material 3TANDARDSFORINSTALLATIONSIN
United States
0LASTICPIPINGMATERIALS 6ENTORAIRPIPING
Vent or air pipe
&

PVC schedule 40 (Note 1) ANSI/ASTM D1785
PVC-DWV schedule 40 (Note 1) ANSI/ASTM D2665
CPVC schedule 40 (Note 1) ANSI/ASTM F441
ABS-DWV schedule 40 (Intake Only) ANSI/ASTM D2661
PVC & ABS pipe
cement & primer
PVC (Note 1) ANSI/ASTM D2564/F656
CPVC (Note 1) ANSI/ASTM F493
ABS schedule 40 (Note 1) ANSI/ASTM D2235
Polypropylene

terminations and
cement
3IMPSON$URAVENT Obtain all materials from
M&G Simpson-Duravent
#ENTROTHERM%CO3YSTEMS)NNO&LUE®3INGLE
WALLObtain all materials from Centrotherm
See manufacturer’s literature for detailed information
MUST USE LOCKING COLLAR ON EVERY JOINT
!,#STAINLESSSTEELPIPINGMATERIALS
Vent pipe
AL29-4C
stainless
steel
Heat Fab, Inc. — Saf-T-Vent®
Z-Flex, Inc. — Z-Vent II
Dura-Vent — FasNSeal®
Metal-Fab, Inc. — CORR/GUARD
Certified for direct vent appliance venting
3TAINLESSSTEELBIRDSCREENSvORv(purchase separately) — see Figure 164, page 121 for part numbers
Note 1: Williamson-Thermoflo concentric vent kits are made
from PVC pipe and fittings.
DO NOT mix piping from different pipe manufac-
turers unless using adapters specifically designed
for the purpose by the manufacturer.
Every joint on polypropylene vent piping must
include a locking collar.
DO NOT use cellular core PVC (ASTM F891), cellular
core CPVC, or Radel®(polyphenolsulfone) in vent-
ing systems.
DO NOT cover non-metallic vent pipe and fittings
with thermal insulation.
ADAPTERS – The boiler comes with a 3”,
3-in-1 adapter as standard. This adapter allows the
installation of 3”PVC schedule 40, CPVC schedule 40,
PVC-DWV schedule 40, AL29-4C stainless steel and
Polypropylene (from Simpson-Duravent only) piping
without the need for extra adapters.
It may require an adapter at terminations.
If your venting system uses Centrotherm Eco systems
InnoFlue single wall material, then an approved
adapter is required.
If using 2”piping (FS-80/120 only), where approved
for the application, provide adapters for a 3” pipe
material (mentioned above) connections and at
the terminations, if required.

Part number 550-142-950/0919
18
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
7 Commonwealth of Massachusetts installations
A&ORALL SIDEWALLHORIZONTALLYVENTEDGASFUELEDEQUIPMENT
installed in every dwelling, building or structure used in
WHOLEORINPART FOR RESIDENTIAL PURPOSESINCLUDING THOSE
owned or operated by the Commonwealth and where the
SIDEWALLEXHAUSTVENTTERMINATIONISLESSTHANSEVENFEET
ABOVElNISHEDGRADEINTHEAREAOFTHEVENTINGINCLUDINGBUT
NOTLIMITEDTODECKSANDPORCHESTHEFOLLOWINGREQUIREMENTS
shall be satisfied:
1. ).34!,,!4)/. /& #!2"/. -/./8)$% $%4%#-
TORS!TTHETIMEOFINSTALLATIONOFTHESIDEWALLHORIZON-
TALVENTEDGASFUELEDEQUIPMENTTHEINSTALLINGPLUMBEROR
gas fitter shall observe that a hard wired carbon monoxide
detector with an alarm and battery back-up is installed on
the floor level where the gas equipment is to be installed.
In addition, the installing plumber or gas fitter shall
observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each ad-
DITIONALLEVELOFTHEDWELLINGBUILDINGORSTRUCTURESERVED
BYTHESIDEWALLHORIZONTALVENTEDGASFUELEDEQUIPMENT
)TSHALL BE THE RESPONSIBILITYOF THE PROPERTYOWNER TO
SECURETHESERVICESOFQUALIlEDLICENSEDPROFESSIONALSFOR
THEINSTALLATIONOFHARDWIREDCARBONMONOXIDEDETECTORS
a. In the event that the side wall horizontally vented gas
FUELEDEQUIPMENTISINSTALLEDINACRAWLSPACEORAN
attic, the hard wired carbon monoxide detector with
alarm and battery back-up may be installed on the
next adjacent floor level.
B)NTHEEVENTTHATTHEREQUIREMENTSOFTHISSUBDIVISION
CANNOTBEMETATTHETIMEOFCOMPLETIONOFINSTALLA-
TIONTHEOWNERSHALLHAVEAPERIODOFTHIRTYDAYS
to comply with the above requirements; provided,
however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an
alarm shall be installed.
2. !002/6%$#!2"/.-/./8)$%$%4%#4/23%ACH
carbon monoxide detector as required in accordance with
THEABOVEPROVISIONSSHALLCOMPLYWITH.&0!LATEST
EDITIONANDBE!.3)5,LISTEDAND)!3CERTIlED
3. 3)'.!'%!METALORPLASTICIDENTIlCATIONPLATESHALL
BEPERMANENTLYMOUNTEDTO THEEXTERIOROF THE BUILD-
INGATAMINIMUMHEIGHTOFEIGHTFEETABOVEGRADE
DIRECTLYIN LINE WITHTHEEXHAUSTVENTTERMINALFORTHE
HORIZONTALLYVENTEDGAS FUELED HEATING APPLIANCEOR
equipment. The sign shall read, in print size no less than
ONEHALFINCHINSIZEh'!36%.4$)2%#4,9"%-
,/7+%%0#,%!2/&!,,/"3425#4)/.3v
4. ).30%#4)/.4HESTATEOR LOCAL GAS INSPECTOR OFTHE
SIDEWALLHORIZONTALLYVENTEDGASFUELEDEQUIPMENTSHALL
not approve the installation unless, upon inspection,
the inspector observes carbon monoxide detectors and
SIGNAGE INSTALLED IN ACCORDANCEWITHTHEPROVISIONSOF
#-2ATHROUGH
(b) %8%-04)/.34HE FOLLOWINGEQUIPMENT IS EXEMPTFROM
#-2ATHROUGH
 4HEEQUIPMENTLISTEDIN#HAPTERENTITLEDh%QUIPMENT
.OT2EQUIRED4O"E6ENTEDvINTHEMOSTCURRENTEDITION
OF.&0!LATESTEDITIONASADOPTEDBYTHE"OARDAND
 0RODUCT!PPROVEDSIDEWALLHORIZONTALLYVENTEDGASFUELED
EQUIPMENTINSTALLEDINAROOMORSTRUCTURESEPARATEFROM
the dwelling, building or structure used in whole or in
PARTFORRESIDENTIALPURPOSES
(c) -!.5&!#452%22%15)2%-%.43'!3%15)0-%.4
6%.4).'3934%-02/6)$%$7HENTHEMANUFACTUREROF
0RODUCT!PPROVEDSIDEWALLHORIZONTALLYVENTEDGASEQUIP-
ment provides a venting system design or venting system
components with the equipment, the instructions provided
BYTHEMANUFACTURERFORINSTALLATIONOFTHEEQUIPMENTAND
the venting system shall include:
 $ETAILEDINSTRUCTIONSFORTHEINSTALLATIONOFTHEVENTING
system design or the venting system components; and
 !COMPLETEPARTSLIST FOR THE VENTINGSYSTEMDESIGN OR
venting system.
(d) -!.5&!#452%22%15)2%-%.43'!3%15)0-%.4
6%.4).'3934%-./402/6)$%$7HENTHEMANUFAC-
TUREROFA0RODUCT!PPROVEDSIDEWALLHORIZONTALLYVENTEDGAS
FUELEDEQUIPMENTDOESNOTPROVIDETHEPARTSFORVENTINGTHE
mUEGASESBUTIDENTIlEShSPECIALVENTINGSYSTEMSvTHEFOLLOW-
INGREQUIREMENTSSHALLBESATISlEDBYTHEMANUFACTURER
 4HEREFERENCEDhSPECIALVENTINGSYSTEMvINSTRUCTIONSSHALL
be included with the appliance or equipment installation
instructions; and
 4HEhSPECIALVENTINGSYSTEMSvSHALLBE0RODUCT!PPROVED
BYTHE"OARDANDTHEINSTRUCTIONSFORTHATSYSTEMSHALL
include a parts list and detailed installation instructions.
E!COPYOFALLINSTALLATIONINSTRUCTIONSFORALL0RODUCT!PPROVED
SIDEWALLHORIZONTALLYVENTEDGASFUELEDEQUIPMENTALLVENTING
INSTRUCTIONSALLPARTSLISTSFORVENTINGINSTRUCTIONSANDORALL
venting design instructions shall remain with the appliance
OREQUIPMENTATTHECOMPLETIONOFTHEINSTALLATION
Commonwealth of Massachusetts — 8IFOUIFCPJMFSJTJOTUBMMFEXJUIJOUIF$PNNPOXFBMUIPG.BTTBDIVTFUUT
UIFCPJMFSNVTUCFJOTUBMMFECZBMJDFOTFEQMVNCFSPSHBTmUUFS3FBEBOEDPNQMZXJUIUIFJOTUSVDUJPOTCFMPX

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. The vent termination clearances below are for U.S.A. Consideration should be given to avoid possible damage

ft. (1.22m) horizontally from, and in no case above or below, unless a 4 ft. (1.22m) horizontal distance is maintained, from electrical
meters, gas meters, regulators, and relief equipment.
Part number 550-142-950/0919 19
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
8 Vent termination requirements
.*/*.6.$-&"3"/$&4
%003 01&/"#-&
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'03$&%"*3
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JGXJUIJOGFFU
IPSJ[POUBMMZ
GFFUBCPWF
JGXJUIJOGFFU
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/0/.&$)"/*$"-
"*3*/5",&
GPPUBCPWFPS
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GFFUIPSJ[POUBMMZ
%0/055&3.*/"5&
GFFUNJO
300'
07&3)"/(
8"--
GFFUNJOUPBXBMMPS
16#-*$8"-,8":
7&/5
7&/5
7&/5 7&/5 7&/5
(3"%&PS4/08-*/&
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DMFBSPGBDDVNVMBUJOHTOPX
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%0/05UFSNJOBUFBCPWFB
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DPOEFOTBUFDBOGSFF[FBOE
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TVSGBDFTEVFUP
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Part number 550-142-950/0919
20
FreeStyle® Series 2 wall mount gas-fired water boiler — Boiler Manual
9 Boiler room air openings
Figure 23 #OMBUSTIONANDVENTILATIONAIROPENINGSFORFreeStyle®$IRECT6ENTINSTALLATIONS0ROVISIONSFORCOMBUSTION
ANDVENTILATIONAIRTOBENACCORDANCEWITHTHESECTIONh!IRFOR#OMBUSTIONAND6ENTILATIONvOFTHE.ATIONAL&UEL
'AS#ODE!.3):.&0!LATESTEDITIONORAPPLICABLEPROVISIONSOFTHELOCALBUILDINGCODES
The FreeStyle®BOILER#!../4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.
Air openings
4HEREQUIREDAIROPENINGSIZESBELOWARE&2%%!2%!
AFTERREDUCTIONFORLOUVEROBSTRUCTION.OTETHEEX-
CEPTIONBELOWFORLARGESPACES
FreeStyle®boiler
WITH other
appliances in room
FreeStyle®boiler
WITHOUT other
appliances in room
TWO openings, each at least:
1square inch per  Btuh
of all other appliances in the room
(Unless specified otherwise by
appliance manufacturer)
./ openings are required if the
boiler installation provides at least the
recommended service clearances
shown in Figure 1, page 5.
Provide openings ONLY as shown
in Figure 1, page 5.
Each opening must have a free
area no less than 1 square inch per
1,000 Btuh input of the boiler.
TWO openings, each at least:
1square inch per  Btuh
of all other appliances in the room
— OR —
/.% opening **, each at least:
1square inch per  Btuh
of all other appliances in the room
(Unless specified otherwise by
appliance manufacturer)
TWO openings, each at least:
1square inch per  Btuh
of all other appliances in the room
— OR —
/.% opening **, each at least:
1square inch per  Btuh
of all other appliances in the room
(Unless specified otherwise by
appliance manufacturer)
TWO openings, each at least:
1square inch per  Btuh
of all other appliances in the room
— OR —
/.% opening **, each at least:
1square inch per  Btuh
of all other appliances in the room
(Unless specified otherwise by
appliance manufacturer)
./4)#%
2EQUIREMENTSFORUSINGTHE3).',%AIROPENING
OPTION
A single combustion air opening can be used for cases b, c or d above ( FreeStyle
®
with other appliances in room only), sized as listed, provided that:
s The single opening must communicate directly to the outdoors or to a space that
communicates directly with outdoors (NOT to an interior space).
s The top of the opening must be within 12 inches of the ceiling.
s The free area of the opening must be at least equal to the sum of the areas of all
equipment vent connectors in the space.
30%#)!,%8#%04)/.&/2,!2'%30!#%3
(FreeStyle®7)4(OTHERAPPLIANCESINROOM
ONLY
NO combustion air openings are needed if the boiler (and other appliances) are
installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btuh of all
appliances in the space. That is, total the input of all appliances in MBH (1,000’s of
Btuh), then multiply this total times 50. The building MUST NOT be of tight construction.
Example: For a total input of 500 MBH (500,000 Btuh), the minimum volume would
be 50 x 500 = 25,000 cubic feet.