Freestyle FS-120 LP Instruction Manual Download Page 1

Page: 1 / 120

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.

7HENCALLINGORWRITINGABOUTTHEBOILER0LEASEHAVEsBOILERMODELNUMBERFROMTHEBOILERRATINGLABEL

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

s3TARTUP

s-AINTENANCE

s0ARTS

Summary of Contents for FS-120 LP

Page 1: ...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 BO...

Page 2: ...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 wi...

Page 3: ...E 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 S...

Page 4: ...it 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...

Page 5: ...BURNS ALLOW BOILER TO COOL BEFORE PER FORMING MAINTENANCE 3 This boiler contains ceramic ber and berglass materi ALS 2EFER TO THE7 2 AND INSTRUCTIONS ON page 73 OMMONWEALTH OF ASSACHUSETTS F THE BOILE...

Page 6: ...nnot 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...

Page 7: ...ings 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...

Page 8: ...ive 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 tting must be install...

Page 9: ...ecure 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...

Page 10: ...ER 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...

Page 11: ...the relief valve tapping of the reducing tee 4HIS 534 2 6 after the test and the relief valve mounted here 4 Pressure temperature gauge eld supplied by installer 5a Reducing tee NPT x x on FS 80 120 5...

Page 12: ...rinstallationof this kit Theinstallationisnotproperandcompleteuntil theoperationof theconvertedapplianceischeckedas speci edinthemanufacturer sinstructionssupplied withthekit s Follow all instructions...

Page 13: ...ual 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 t...

Page 14: ...15 1 Control panel page 13 2 AS VALVE PAGE 3 AS PIPE 4 Washer 5 Phillips head screws 6 AS VALVE VENTURI 7 O Ring 8 Blower 4 Remove three 3 Phillips head screws holding the ven turi Item 5 in place rem...

Page 15: ...ATED FOR EACH FT ABOVE SEA LEVEL BEYOND FT IN ACCORDANCE WITH ATIONAL UEL AS ODE 3 0 13 Using a combustion analyzer insert probe into the ue test point check that the CO2 content in the exhaust with t...

Page 16: ...IONS BEGINNING ON page 12 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 suppl...

Page 17: ...wing 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...

Page 18: ...Size inches Materials Fig 16 page 17 Size inches Materials Fig 16 page 17 Size inches Materials Fig 16 page 17 Size inches Materials Fig 16 page 17 Size inches Materials Fig 16 page 17 FS 80 2 PVC PVC...

Page 19: ...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 venting systems DO NOT cover non metallic...

Page 20: ...ONTALLY 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 LOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 30 4 4HE STATE OR LOCAL...

Page 21: ...RMINATION MUST BE LOCATED TO MEET ALL REQUIREMENTS BELOW ALSO APPLIES TO VERTICAL VENT TERMINATIONS Part number 550 142 850 0115 21 FreeStyle WALL MOUNT GAS FIRED WATER BOILER Boiler Manual 8 Vent ter...

Page 22: ...nings each at least 1 square inch per Btuh of all other appliances in the room OR opening each at least 1 square inch per Btuh of all other appliances in the room Unless speci ed otherwise by applianc...

Page 23: ...HE AIR INLET OF A FreeStyle BOILER IS PART OF A DIRECT VENT CONNECTION T IS NOT CLASSIlED AS A FORCED AIR INTAKE WITH REGARD TO SPACING FROM ADJACENT BOILER VENTS 0REPARE WALL PENETRATIONS 1 Air pipe...

Page 24: ...mination elbow by inser ting bird screens See Figure 24 page 23 Bird screens must be purchased SEPARATELY 3EE THE PARTS LIST AT THE END OF THIS MANUAL FOR part numbers 2 Secure the elbows so they will...

Page 25: ...tric termination as described in this manual All vent pipes and air inlets must terminate AT THE SAME HEIGHT TO AVOID POSSIBILITY OF severe personal injury death or substantial property damage 2 Place...

Page 26: ...gure 29 4 EFORE BEGINNING VENT AND AIR PIPING FROM THE BOILER TO THE CON centric termination mount and secure the concentric termination as shown in Figure 29 The vent and air piping must be securely...

Page 27: ...0 73 2 6 4 2 0 0 4 USE SHORT RADIUS ELBOWS FOR VENT OR AIR PIPING OILER PERFORMANCE COULD BE AFFECTED Part number 550 142 850 0115 27 FreeStyle WALL MOUNT GAS FIRED WATER BOILER Boiler Manual Allowab...

Page 28: ...TURER S instructions Termination and ttings 1 Prepare the vent termination elbow and the air termina tion elbow Figure 30 page 27 by inserting bird screens Bird screens must be purchased separately Se...

Page 29: ...s as described in this manual All vent outlets must terminate at the same HEIGHT TO AVOID POSSIBILITY OF SEVERE PERSONAL injury death or substantial property damage 2 0LACE ROOF PENETRATIONS TO OBTAIN...

Page 30: ...d must not rest its weight on the boiler ttings DO NOT drill or screw into either the vent pipe or air pipe Failure to properly support the vent and air piping could result in vent pip ing damage resu...

Page 31: ...AND ALL SUPPORTS HAVE been installed Follow instructions to cover THE END OF THE ASSEMBLY WITH PLASTIC BEFORE INSERTING THROUGH THE ROOF PENETRATION TO PREVENT DEBRIS FROM BLOCKING THE AIR PASSAGES F...

Page 32: ...R EITHER THE air or vent piping 2 OILER HAS TWO AIR INLETS LEFT AND RIGHT OF CENTERED mUE OPENING PRE DETERMINE WHETHER USING LEFT OR RIGHT FOR AIR inlet piping 3 See Figure 36 FOR LOCATIONS FOR ATTAC...

Page 33: ...T HECK JOINT TO BE SURE A SMOOTH BEAD OF CEMENT SHOWS AROUND THE entire joint 14 3EAL WALL OR mOOR PENETRATION OPENINGS FOLLOWING LOCAL code requirements 04 23 5SEADAPTERSIF USINGOTHERTHAN INCH06 OR 0...

Page 34: ...ess the con guration menu 1 0RESS THE 7 AND 7 n BUTTONS TOGETHER FOR seconds 2 T THE END OF THE SECONDS THE DISPLAY WILL SHOW THE message B 3 0RESS THE HEATING BUTTONS OR TO SCROLL UP THE LIST OF para...

Page 35: ...7 0RESSURE 2ATING 03 4 5 130 Hot Water Can Scald s ONSUMER 0RODUCT 3AFETY OMMISSION AND SOME states recommend domestic hot water tempera TURE OF OR LESS s When installing an automatic mixing valve se...

Page 36: ...PERATURE SYSTEMS F USING TEMper ature limited materials such as PEX tubing in system piping it is recommended to protect the system with limit controls that are wired to the controls external limit ci...

Page 37: ...LOAD FOR THE CIRCUIT 7 BTUH n n n n 4 X XAMPLES 1 ONSIDER A SYSTEM LOOP FOR A SYSTEM WITH TOTAL HEATING LOAD EQUAL to 210 000 Btuh The desired temperature drop through the system piping is 20 F Then...

Page 38: ...ear Boiler Piping Recommended Circulators 3 4 Pipe 1 Pipe 3 4 Pipe 1 Pipe 3 4 Pipe 1 Pipe 3 HEAT ONLY 20 7 4 7 8 12 5 3 0 20 3 10 8 A B C D 30 4 9 4 0 6 0 1 5 10 0 5 5 B C D E B C D E 40 3 7 2 7 3 5 0...

Page 39: ...HE SYSTEM AND WILL CAUSE WATER LOGGING OF THE TANK 4HIS WILL RESULT IN WATER LOSS THROUGH THE BOILER RELIEF valve due to over pressurization NEVER use an automatic air vent in a system equipped with a...

Page 40: ...M THE TOP OF THE BOILER Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length ISCHARGE LINE MUST PITCH DOWNWARD FROM THE VALVE...

Page 41: ...those listed in Figure 47 page 38 must pipe the boiler loop as a secondary circuit as show 3YSTEMS ZONED WITH ZONE VALVES 534 USE A BY PASS PRESSURE regulator NSTALL A SYSTEM CIRCULATOR SUPPLIED BY I...

Page 42: ...HEATING ZONES TO INPUTS AND OUTPUTS INTENDED FOR DHW applications may violate Section303of the2007 Energy Act See page 119 FOR COMPLIANCE INFORMATION and exemptions Wiring the Indirect tank aquastat t...

Page 43: ...D FOR THE HI TEMP ZONES 4HE mixing device regulates supply temperature to the lower temp zones Domestic Hot Water DHW tank if used 1 7 DIRECT CONNECTION 0IPE FROM THE NEAR BOILER PIPING TO THE 7 TANK...

Page 44: ...D BOILERS FOR ACCESS AND SER VICING F RECOMMENDED DIMENSIONS ARE NOT POSSIBLE PROVIDE AT LEAST THE MINIMUM CLEARANCES GIVEN ON PAGE LSO FOLLOW local codes 3 0ROVIDE A MINIMUM INCH WALKWAY IN FRONT OF...

Page 45: ...irculator 5 Expansion tank diaphragm type 6 System air eliminator 7 System automatic air vent 8 Pressure reducing valve Check valve or back ow preventer as required by appli cable codes 10 Cold water...

Page 46: ...2 0IPE FROM THE NEAR BOILER PIPING TO THE 7 TANK S boiler connections as shown in Figure 50 page 41 3 Connect the DHW tank aquastat directly to the DHW input on the last boiler in the sequence When u...

Page 47: ...34 D1785 F441 or D2665 Cement and primer MUST COMPLY WITH 34 OR 2 3ELECT A CONDENSATE PUMP IF USED THAT IS APPROVED FOR USE WITH CONDENSING BOILERS AND FURNACES 4HE PUMP should have an over ow switch...

Page 48: ...EFORE PLACING BOILER IN OPERATION CHECK BOILER AND ITS GAS CONNECTION FOR LEAKS a During any pressure testing at less than 13 w c close THE GAS SHUTOFF VALVE AND DISCONNECT SYSTEM GAS PIPING At highe...

Page 49: ...3 5 w c c Nominal gas pressure 11 0 w c 4 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 20 Gas piping...

Page 50: ...rounded as required by National Electrical Code ANSI NFPA 70 latest edition LL lELD WIRING IS MADE THROUGH THE BOTTOM OF THE BOILER through two 2 black grommets shown in Figure 61 ONNECTING TERMINALS...

Page 51: ...e heated boiler water to the indirect tanks heating coil s Field supplied zone panel with priority zone indirect circulator ZONE VALVE FOR INDIRECT TANK s Connect indirect aquastat N O contact wires t...

Page 52: ...Combi 186 Return temperature sensor 191 Exhaust temperature sensor 278 Double sensor heating safety 279 Transformer 115 24 Vac 284 Relay SPST Coil 24 Vac 370 LWCO optional 373 OPENTHERM communication...

Page 53: ...or 44 Gas valve 72 Room thermostat optional 81 Ignition electrode 95 Mixing diverting valve 104 1 Fuse 3 15A 104 1 Fuse 630mA 114 Water pressure switch 136 Flow meter 138 Outside temperature sensor op...

Page 54: ...rn temperature sensor 191 Exhaust temperature sensor 278 Double sensor heating safety 279 Transformer 115 24 Vac 284 Relay SPST Coil 24 Vac 370 LWCO optional 373 OPENTHERM communication Not used NOTES...

Page 55: ...ump not included 44 Gas valve 72 Room thermostat optional 81 Ignition electrode 104 1 Fuse 3 15A 104 1 Fuse 630mA 114 Water pressure switch 130 DHW Pump not included 138 Outdoor sensor 143 DHW tank th...

Page 56: ...Natural gas or Lique ed Petroleum Propane gas generating extremely low emissions The boiler is constructed with a stainless steel heat exchanger PROVIDING EFFECTIVE CONDENSATION OF THE WATER VAPOR CON...

Page 57: ...gure 72 page 56 The display indicates the actual Central Heating water temperature Item 11 Figure 72 page 56 and when the required temperature is reached d2 will be displayed Domestic hot water operat...

Page 58: ...HE EXTERNAL CONTROLS ARE CALLING FOR HEAT Figure 77 4URNING OFF MODE Turning off 0RESS THE ON OFF BUTTON TEM Figure 72 page 56 FOR SECONDS To totally isolate close the gas cock before the boiler and d...

Page 59: ...special internal device that ensures a HIGH HOT WATER DELIVERY SPEED AND EXCELLENT USER COMFORT 7HEN COMFORT MODE IS ACTIVE THE WATER IN THE BOILER IS MAINTAINED AT a pre determined temperature which...

Page 60: ...TTLE HEAT LOSS SUCH AS A SUPER INSULATED HIGH EFlCIENCY BUILDING WOULD BE curve number 1 where the outdoor temperatures continue to drop and the boiler water temperatures are in the low RANGE FROM DEG...

Page 61: ...this to 190 F A lower supply temperature can be used but will reduce the indirect water heater heating capacity Figure 83 OMPENSATION PARALLEL OFFSET CURVES 4YPICAL LOW TEMPERATURE RADIANT APPLICATIO...

Page 62: ...tor TURNS OFF WHEN THE TEMPERATURE RISES ABOVE 25 DHW Settings Combi Only continued Model 3TANDARD LTITUDE AN 3PEED Z Low Fire B06 Ignition Can t Change Needs PC High Fire In CH Mode B05 High Fire In...

Page 63: ...the next zone Follow this proce dure until all zones are purged Follow the same procedure TO PURGE AIR FROM THE BOILER AND ITS INTERNAL PIPING 7 Close the quick ll water valve and drain valve and remo...

Page 64: ...Part number 550 142 850 0115 64 FreeStyle WALL MOUNT GAS FIRED WATER BOILER Boiler Manual 27 Startup continued 8 FTER THE SYSTEM HAS OPERATED FOR A WHILE ELIMINATE ANY RESIDUAL AIR BY using the manual...

Page 65: ...ENT LOCATIONS ILL CONDENSATE TRAP WITH WATER 1 Loosen the nut that secures the condensate trap body to the boiler condensate connection see Figure 91 Pull the trap DOWN TO DISENGAGE FROM HEAT EXCHANGE...

Page 66: ...nd 4 Figure 72 page 56 TOGETHER FOR SECONDS OR LEAVE THE BOILER TO AUTOMATICALLY SWITCH OFF AFTER MINUTES OR STOP ping DHW ow 6 This TEST procedure is used to check adjust combustion CO and CO2 PER SP...

Page 67: ...UCTIONS 7 2 6ERIFY THAT THE FreeStyle CONTROL IS SET FOR THE CORRECT BOILER MODEL BEFORE PROCEEDING Part number 550 142 850 0115 67 FreeStyle WALL MOUNT GAS FIRED WATER BOILER Boiler Manual 28 6WDUWXS...

Page 68: ...9 4EST FOR 2 or O2 AND FOR 4HE 2 values must comply with Figure 95 or Figure 98 page 69 F RESULTS ARE ACCEPTABLE proceed to step 7 4 FOLLOW THE INSTRUCTIONS UNDER Throttle Screw Adjustment on page 69...

Page 69: ...ratio cannot be obtained please contact your Williamson Thermo o representative 5 Should you require any assistance during the set up pro cedure contact yourWilliamson Thermo o representative IF THE P...

Page 70: ...INDICATION OF A LEAK AT ANY JOINT IMMEDIATELY shut down the boiler a F POSSIBLE TIGHTEN THE RETAINING SCREWS OR NUTS WITHOUT over tightening b F THIS DOES NOT CORRECT THE PROBLEM DISASSEMBLE THE comp...

Page 71: ...LLED CONTROLS TESTED AS OUTLINED BY CONTROL MANUFACTURERS OILER SHOULD BE OPERATING AND SHOULD GO OFF WHEN CONTROLS ARE TESTED 6ERIFY CONTROLS CAUSE automatic reset lockout or manual reset lockout as...

Page 72: ...ce and maintenance procedures given throughout this manual and in component literature shipped WITH THE BOILER AILURE TO PERFORM THE SERVICE AND MAINTENANCE COULD RESULT IN DAMAGE TO THE BOILER OR SYS...

Page 73: ...described on page 49 e 4HE COMBUSTION PERFORMANCE AS DESCRIBED ON pages 68 AND FOR COMBUSTION CHECK F OMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE g The person carrying out a combustion...

Page 74: ...ALL SYSTEM OR BOILER LEAKS ONTINUAL FRESH MAKE UP WATER WILL REDUCE BOILER LIFE INERALS can build up in the heat exchanger reducing heat TRANSFER OVERHEATING HEAT EXCHANGER AND CAUSING HEAT EXCHANGER...

Page 75: ...ORMED INSIDE A BUILDING 3 To access the burner remove the heat exchanger cover PLATE FOLLOWING THE PROCEDURE BEGINNING ON PAGE 100 4 F REPLACING THE BURNER ENSURE THE BURNER GASKET IS IN good conditio...

Page 76: ...clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid conta...

Page 77: ...NCH Remove heat exchanger cover plate LONG HANDLED 4ORX DRIVER Remove burner screws 4 4ORX DRIVER For gas valve adjustment ULTIMETER EASUREMENTS ON SENSORS AND ELECTRICAL COMPONENTS ANOMETER NCLINED O...

Page 78: ...THE TIMING OF THE CYCLES N YOUR TROUBLESHOOTING REFER TO THE NUMBERS THROUGH AS THEY DESCRIBE EACH STEP OF THE IGNITION CYCLE 32 Troubleshooting continued Figure 102 4IME LINE OF IGNITION SEQUENCE FOR...

Page 79: ...l or any major components blower ETC F A FUSE IS BLOWN IT CAN PREVENT FreeStyle control or other components FROM OPERATING 1 Turn OFF power to boiler at external line switch Then remove the jacket doo...

Page 80: ...Av CODES WHICH BLOCKS THE HEAT DEMAND 0RESS RESET BUTTON FOR SECOND TO RESET b Blocking condition codes F codes cause temporary shutdowns that are automatically reset as soon as the valve returns with...

Page 81: ...d 3 times in the last 24 hours See fault F07 A05 Fan protection activated Fault F15 generated for 1 hour con secutive See fault F15 A06 1R DPH DIWHU LJQL tion stage 6 times in 4 minutes Ignitor electr...

Page 82: ...place the sensor Sensordisconnectedafteractivatingthe sliding temperature Reconnect the outdoor sensor or disable the sliding temperature A41 Sensor positioning Supply sensor disconnected from pipe Ch...

Page 83: ...CH installation is too low F39 Outside sensor error F40 The water pressure in the CH installation is too high F43 Heat exchanger protection F47 Water pressure sensor not connected F50 Variable input...

Page 84: ...of new burner request the fan is switched on if the controller measured a frequency ORZHU WKDQ RU KLJKHU WKDQ HUURU ZLOO EH VHW ZLWK D FRQ UPLQJ WLPH RI VHFRQGV Q FDVH VSHHG is back to the normal ope...

Page 85: ...FRQ JXUDWLRQ SDUDPHWHU LV VHW WR LQ WKLV FDVH WKH IXQFWLRQ LV DFWLYH DV VRRQ DV WKH DV YDOYH RSHQLQJ PRPHQW Q FDVH FRQ JXUDWLRQ SDUDPHWHU LV VHW WR DQG LQ FDVH RI PRGH LV UXQQLQJ DQG QVWDOOHU 7HVW PRG...

Page 86: ...erature F 185 PVC CPVC sel dependent b17 0DLQ VXSSO IUHTXHQF 1 b18 RPIRUW RQ WLPH 6HF FRQ J 1RW LPSOHPHQWHG FRQ J 1RW LPSOHPHQWHG FRQ J 1RW LPSOHPHQWHG FRQ J 15 DHW conf dependent b19 RZ VHQVRU OWHU 6...

Page 87: ...ting tS the display starts with showing 0 v BLINKING Y MEANS OF THE AND PUSH BUTTONS IT IS POSSIBLE TO SELECT the parameters between 0 and P34v 3ELECTING ONE OF THESE PARAMETERS BY MEANS OF THE 7 AND...

Page 88: ...LPH 6HF FRQ J SXPS RYHU UXQ WLPH 6HF FRQ J 3 30 30 30 DHW conf dependent P20 DHW maximum output 100 P21 FRPIRUW RII WLPH 0LQ FRQ J 1RW LPSOHPHQWHG FRQ J 1RW LPSOHPHQWHG FRQ J 1RW LPSOHPHQWHG FRQ J 20...

Page 89: ...TION HAS BEEN TAKEN THE AUTOMATICALLY LEAVES THIS MODE AFTER MINUTES In as Inquiry mode Selecting In the display starts with showing T v BLINKING Y MEANS OF THE AND PUSH BUTTONS IT IS POSSIBLE TO SELE...

Page 90: ...OR SECONDS IT IS POSSIBLE TO LEAVE THE NSTALLER MODE F NO ACTION HAS BEEN TAKEN THE AUTOMATICALLY LEAVES THIS MODE AFTER MINUTES Hi as History mode Selecting Hi the display starts with showing v BLINK...

Page 91: ...r Num 0 255 15 FRQ J 10 1 CL5 0691 DHW I factor Num 0 255 240 FRQ J 11 1 ML 80EB DHW FF factor Num 0 255 0 FRQ J 12 1 ML 80EC Fan absolute DHW maximum speed Hz 0 220 200 FRQ J 13 1 ML 80ED Fan absolut...

Page 92: ...20 200 FRQ J 14 2 ML 80EE Fan absolute minimum speed Hz 0 165 40 FRQ J 15 2 CL5 2D89 Fan offset low level Hz 0 220 10 FRQ J 16 2 ML 80F0 Ignition level 0 100 60 FRQ J 17 2 Free TBD FRQ J 18 2 Free TBD...

Page 93: ...23 3 ML 80F7 DHW over temp_burnerOFF solar F 0 200 18 FRQ J 24 3 ML 80F8 DHW over temp_burnerON solar F 0 200 18 FRQ J 25 3 ML 80F9 DHW start waiting time solar1 Sec 0 255 5 FRQ J 26 3 ML 80FA DHW st...

Page 94: ...art waiting time Sec 0 255 0 FRQ J 32 4 CL5 05A1 DHW OFF time Sec 30 255 120 FRQ J 33 4 CL5 0A04 DHW pump over run time Sec 0 255 30 FRQ J 34 4 CL5 0A6D Delta T1 F 0 108 32 FRQ J 35 4 CL5 0A92 Delta T...

Page 95: ...5 2EDF Water pressure high limit psi 36 50 41 System 75 ML 8128 DWHU OOLQJ PRGH Num 0 1 0 System 76 ML 811B Main supply frequency Num 0 1 1 System 77 ML 80DC Variable output relay functionality Num 0...

Page 96: ...ppened LSB Num History 118 ML 8031 Hour when History error 5 is happened MSB Num History 119 ML 8036 Hour when History error 6 is happened LSB Num History 120 ML 8035 Hour when History error 6 is happ...

Page 97: ...156 1 ML 80DF Peak pump on fan speed Hz 0 255 120 FRQ J 157 1 ML 80D8 Peak pump switch on time Sec 0 255 20 FRQ J 158 1 ML 80CD Peak remove time Sec 0 20 0 FRQ J 159 1 ML 80CE Peak remove switch off t...

Page 98: ...l water set point F Boiler 9 CL4 FC02 MSB CH Virtual set point F Boiler 10 CL4 FC02 LSB DHW Virtual set point F Boiler 11 CL4 11DC MSB Fan speed Setpoint Hz Boiler 12 CL4 11DC LSB Fan speed Feedback H...

Page 99: ...ve the ignitor wire by pulling on the connector not the wire Figure 128 NSPECTING IGNITION ELECTRODE Disconnect power Electrical shock hazard Disconnect ALL ELECTRICAL POWER TO THE BOILER BEFORE attem...

Page 100: ...ITER CERAMIC is cracked or damaged replace 7 Reinstall ignition electrode making sure gasket is in good condition and correctly positioned 4 215 4 Useatorquewrenchwhentight ening the two 2 ignition el...

Page 101: ...T s CLEAN WITH A WATER SPRAY FROM INSIDE THE BURNER s SWIRL THE BURNER THOROUGHLY IN A BUCKET OF MILD LIQUID laundry detergent water then rinse thoroughly 7 Inspect the burner exterior It must be in g...

Page 102: ...r to remove any accumulation on the HEATING SURFACES 4HIS INCLUDES REMOVING ANY PIECES OF REFRAC tory that may have dropped into the exchanger Figure 137 LEANING THE HEAT EXCHANGER Figure 138 LEANING...

Page 103: ...eration on the sealed control parts s EFORE CARRYING OUT ANY CLEANING OR MAINTENANCE OPERATION DISCONNECT THE UNIT FROM THE ELECTRICAL POWER SUPPLY USING THE SWITCH AND OR THE SPECIAL CUT OFF DEVICES...

Page 104: ...changer system delivery 1 and Heat exchanger system return 5 s PEN THE VALVE OF EAT EXCHANGER SYSTEM SUPPLY AND RETURN PLACED BEFORE THE BOILER CONNECTIONS s Reconnect the unit to the electrical power...

Page 105: ...L CUT OFF DEVICES AND TURN IT 16 HECK THE CORRECT OPERATION OF THE BOILER AND FUNCTIONALITY OF PRODUCTION OF DOMESTIC HOT WATER Hot Water Can Scald s ONSUMER 0RODUCT 3AFETY OMMISSION AND SOME STATES R...

Page 106: ...e same orientation The next two gures are for illustrating and information only The gas valve does NOT need to be removed to replace brazed plate heat exchanger 8 Flat plate heat exchanger can be imme...

Page 107: ...CHANGER SLIGHTLY UP AND ALIGN WITH 7 connections reinstall the two 2 Phillips head screws tighten SECURELY 4ORQUE TO LB FT LB FT When re installing components make sure gas kets are in good condition...

Page 108: ...REPLACEMENT PART 2ESULTS FROM USING MODIlED OR OTHER MANUFACTURED PARTS WILL NOT be covered by warranty and may damage boiler or impair operation The boiler contains ceramic ber materials 4HE BOILER C...

Page 109: ...PVC concentric vent kit horizontal or vertical includes components for concentric assembly Kit for 2 PVC vent and air pipes Kit for 3 PVC vent and air pipes 383 700 167WT 383 500 350WT Bird screens 1...

Page 110: ...ED WATER BOILER Boiler Manual 34 Replacement parts continued Item Name Part Number 100 Jacket door 640 000 002WT 110 Jacket left side 640 000 000WT 120 Jacket right side 640 000 001WT Figure 150 ACKET...

Page 111: ...Part number 550 142 850 0115 111 FreeStyle WALL MOUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts continued Figure 151 ACKET PARTS FreeStyle SHEET METAL FOR OMBI AND EATING NLY BOILERS...

Page 112: ...rator 640 000 018WT 250 Water Pressure Switch 640 000 019WT 260 Flow Meter 640 000 026WT 270 Water Filter 640 000 027WT 280 Valve 3 Way 640 000 028WT 290 Motor 3 Way Valve 640 000 029WT 300 N R Valve...

Page 113: ...Part number 550 142 850 0115 113 FreeStyle WALL MOUNT GAS FIRED WATER BOILER Boiler Manual Figure 153 OILER REPLACEMENT KITS AND PARTS FreeStyle Combi continued 34 Replacement parts continued...

Page 114: ...Kit Natural Gas Conversion 640 000 022WT 640 000 023WT 210 LW LTXH HG 3HWUROHXP 3URSDQH DV RQYHUVLRQ 640 000 024WT 640 000 025WT 220 Gas Valve VK8205V 640 000 037WT 230 Water Pressure Switch 640 000...

Page 115: ...Figure 155 OILER REPLACEMENT KITS AND PARTS FreeStyle EATING NLY continued Part number 550 142 850 0115 115 FreeStyle WALL MOUNT GAS FIRED WATER BOILER Boiler Manual 34 Replacement parts continued...

Page 116: ...40 000 003WT 110 Control module display cover 640 000 004WT 120 Pressure Temperature assembly Combi 640 000 006WT Pressure Temperature assembly Heating Only 640 000 054WT 130 Wire harness assembly Com...

Page 117: ...tem return tapping NPT 6 Air connection 2 or 3 PVC 7 Flue connection 2 or 3 PVC Heating ONLY ONNECTIONS 1 Heating system supply tapping NPT 3 Gas connection 5 Heat system return tapping NPT 6 Air conn...

Page 118: ...68 0 55 2 or 3 15 0 OTES 1 4OTAL AMP REQUIREMENT INCLUDES UP TO ONE CIRCULATOR OW 7ATER UTOFF 7AY 6ALVE NOT EXCEEDING amps total 2 PERATING WEIGHT IS THE TOTAL WEIGHT OF THE BOILER INCLUDING WATER 3 F...

Page 119: ...due to the pressure loss through the piping For vent air pipe lengths less than the maximum the derate equals the value above times vent length 100 7 CSA Low Lead Content only applies to the Combi bo...

Page 120: ...OODWLRQ DQG 6HUYLFH HUWL FDWH Boiler model _______________________________________________________________ Series ____________ Number _______________________________________ Date installed ___________...

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