Freestyle 80 - Startup

Part number 550-142-850/0716
67
FreeStyle
®
WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
27 Startup
5SETHECORRECTAMOUNTOFANTIFREEZE
1. $ETERMINETHE FREEZING TEMPERATURENEEDEDTOPROTECT
against lowest likely temperature the system water will en-
counter).
2. &INDTHEANTIFREEZECONCENTRATIONBYVOLUMENEEDEDFORTHIS
TEMPERATUREFROMTHEANTIFREEZEMANUFACTURERSDATAONTHE
ANTIFREEZECONTAINER
3. !DDUPTHEVOLUMEGALLONSOFALLSYSTEMPIPINGANDCOM-
ponents, including the expansion tank and boiler.
a. Boiler water content is listed in Figure 166, page 126.
b. Remember to include expansion tank water content.
4. -ULTIPLYTHISVOLUMEBYTHEPERCENTANTIFREEZENEEDEDTO
lNDTHENUMBEROFGALLONSOFANTIFREEZETOADD
Fill and test water system
1. &ILLSYSTEMONLYAFTERENSURINGTHEWATERMEETSTHEREQUIRE-
MENTSOFTHISMANUAL
2. Close manual and automatic air vents and boiler drain valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. 4YPICALCOLDWATERlLLPRESSUREFORARESIDENTIALSYSTEM
is 12 psi.
 "OILERWATERPRESSURESWITCHISSETFORPSIÒ
MINIMUMPRESSURE!LOWWATERPRESSUREWILLGIVE
“F37vFAULTCODE
b. Pressure will rise when boiler is turned on and system
water temperature increases. Operating pressure must
never exceed 25 PSIG.
4. !TINITIAL lLL AND DURING BOILER STARTUPAND TESTINGCHECK
SYSTEMTHOROUGHLYFORANYLEAKS2EPAIRALLLEAKSBEFOREPRO-
CEEDINGFURTHER
 %LIMINATEALLSYSTEMLEAKS#ONTINUALFRESHMAKEUP
WATERWILLREDUCEBOILERLIFE-INERALSCANBUILDUP
INTHEHEATEXCHANGERREDUCINGHEATTRANSFEROVER-
heating heat exchanger, and causing heat exchanger
FAILURE
Purge air from water system
1. Connect a hose to the drain valve (see drain valves, item 10,
in piping diagrams beginning on page 11). Route hose to an
area where water can drain and be seen.
2. Close the boiler or system isolation valve between the drain
valve and fill connection to the system.
3. Close zone isolation valves.
4. Open quick-fill valve on cold water make-up line.
5. Open drain valve.
6. /NEZONEATATIMEOPENTHEISOLATIONVALVES!LLOWWATER
to run through the zone, pushing out the air. Run until
no noticeable air flow is present. Close the zone isolation
valves and proceed with 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-fill water valve and drain valve and remove
the hose. Open all isolation valves. Watch that system pressure
rises to correct cold-fill pressure.
Clean system to remove sediment
1. 9OUMUST THOROUGHLY FLUSHTHESYSTEM WITHOUTBOILER
CONNECTEDTOREMOVESEDIMENT4HEHIGHEFlCIENCY HEAT
exchanger can be damaged by buildup or corrosion due to
sediment.
 )FTHESYSTEMNEEDSTOBECLEANEDUSEONLY3ENTINEL
8CLEANERAVAILABLEFROM7ILLIAMSON4HER-
moflo. See Figure 153, page 113FORINFORMATION
Follow instructions supplied with the X400 cleaner
and cleaning instructions on page 107. For zoned
systems, flush each zone separately through a purge
VALVE)FPURGEVALVESANDISOLATIONVALVESARENOT
already installed, install them to properly clean the
system).
2. Flush system until water runs clean and you are sure piping
ISFREEOFSEDIMENT
Do not use petroleum-based cleaning or seal-
ing compounds in boiler system. Damage to
elastomer seals and gaskets in system could oc-
cur, resulting in substantial property damage.
"EFORElLLINGTHEBOILERANDSYSTEMWITHWATER
VERIFYTHEFOLLOWING"OILERCORROSIONCANOCCUR
 &AILURETOCOMPLYCOULDRESULTINBOILERFAILURE
or unreliable operation.
Water chemistry
7ATERP(BETWEENAND
1. -AINTAINBOILERWATERP(BETWEENAND#HECKWITH
litmus paper or have chemically analyzed by water treatment
company.
2. )FP(DIFFERSFROMABOVECONSULTLOCALWATERTREATMENTCOM-
PANYFORTREATMENTNEEDED
(ARDNESSLESSTHANGRAINS
1. #ONSULTLOCALWATERTREATMENTCOMPANIESFORUNUSUALLYHARD
water areas (above 7 grains hardness).
#HLORIDECONCENTRATIONMUSTBE
,%334(!.PPM
1. &ILLINGWITHCHLORINATEDFRESHWATERSHOULDBEACCEPTABLESINCE
drinking water chloride levels are typically less than 5 ppm.
2. Do not use the boiler to directly heat swimming pool or spa
water.
3. Do not fill boiler or operate with water containing chloride
INEXCESSOFPPM
 6ERIFYTHATTHEWATERCHEMISTRYMEETSTHELIMITA-
TIONSANDREQUIREMENTSOFALLOTHEREQUIPMENTIN
the system.
!NTIFREEZE
1. 5SEONLY ANTIFREEZELISTED BY7ILLIAMSON4HERMOFLO
ASSUITABLE FOR USE WITHFreeStyle® Gas Boilers. See
Figure 153, page 113FORINFORMATION
2. 3EE 2EPLACEMENTPARTS AT THE END OFTHIS MANUAL FOR
7ILLIAMSON4HERMOmOPARTNUMBERS TOOBTAIN ANTIFREEZE
through a Williamson-Thermoflo distributor.