Freestyle 80 - Startup and Final Checks

Check inhibitor concentration
annually
1. 4ESTTHEP(OFASAMPLEOFSYSTEMWATERATLEASTANNUALLY
4HEP(OFTHEWATERMIXTUREMUSTBEBETWEENAND
(Or use the Sentinel inhibitor test kit to check concentra-
tion.)
2. )FP(ISOUTSIDETHISRANGEORINHIBITORTESTKITINDICATES
LOWLEVELTHEINHIBITORLEVELMAYNOTBESUFlCIENTTOPRE-
vent corrosion.
3. 4ESTANTIFREEZECONCENTRATION
 4EST ANTIFREEZECONCENTRATION AT LEAST ANNUALLY
)FCONCENTRATIONISLOWADDANTIFREEZEORDRAIN
system and refill with correct mixture.
4. &OLLOWINSTRUCTIONSONANTIFREEZECONTAINERTODETERMINE
THEAMOUNTOFANTIFREEZENEEDED
$/./4 exceed 50% by
VOLUMECONCENTRATIONOFANTIFREEZE
#HECKINHIBITORLEVELAFTERADJUSTMENTSAREMADE
Check thermostat circuits
1. Disconnect wires connected to the $(7AND(%!4 ther-
mostat terminals (see Field wiring, beginning on page 50
FORLOWVOLTAGETERMINALLOCATIONSANDAPPLICATIONINFOR-
MATION-ARKTHEWIRESBEFOREREMOVINGTOAVOIDWIRING
errors when re-connecting them.
2. #ONNECTAVOLTMETERACROSSEACHPAIROFINCOMINGWIRES
Close each thermostat, zone valve and relay in the external
circuits one at a time and check the voltmeter reading across
the incoming wires.
3.
4HERESHOULD.%6%2BEAVOLTAGEREADING
4. )FAVOLTAGEDOESOCCURUNDERANYCONDITIONCHECKANDCORRECT
the external wiring.
$/ ./4 CONNECT THE FreeStyle
®
thermostat
terminals to 3-wire zone valves
. This could cause
control damage.
5. Once the external thermostat circuit wiring is checked and
CORRECTEDIFNECESSARYRECONNECTTHEEXTERNALTHERMOSTATCIRCUIT
wires.
Inspect/fill condensate system
)NSPECTCHECKCONDENSATELINESANDlTTINGS
1. Inspect the condensate drain line, condensate PVC fittings and
condensate trap. (See page 47FORCOMPONENTLOCATIONS
&ILLCONDENSATETRAPWITHWATER
1. Loosen the nut that secures the condensate trap body to the
boiler condensate connection (see Figure 94). Pull the trap
DOWNTODISENGAGEFROMHEATEXCHANGER<0ULLTHETRAPBODY
FORWARDENOUGHTOALLOWPOURINGWATERINTOTHETOPOFTHETRAP
2. &ILLTHETRAPWITHFRESHWATERUNTILWATERBEGINSTORUNINTOTHE
condensate drain tube.
3. Reattach the trap body by sliding onto the boiler condensate
outlet, then retightening the trap body nut.
.UT
Figure 94 $ISCONNECTCONDENSATETRAPASSEMBLYTOlLL
TRAPBODYWITHWATER
The condensate trap must be filled with water during
ALLTIMESOFBOILEROPERATIONTOAVOIDmUEGASEMISSION
FROMTHECONDENSATEDRAINLINE&AILURETOlLLTHETRAP
could result in severe personal injury or death.
 )FIT IS SUSPECTEDTHATTHECONDENSATEDRAIN CON-
nection is or was blocked, then boiler components
like the gas valve, blower venturi, igniter and heat
EXCHANGERNEEDTOBEINSPECTED#HECKFORDAMAGES
OCCURRINGFROMWATERACCUMULATIONINTHISCABINET
!NYDAMAGED COMPONENTSNEED TO BEREPLACED
Failure to replace water damaged components could
result in severe personal injury or death.
Part number 550-142-850/0716
69
FreeStyle
®
WALL MOUNT GAS-FIRED WATER BOILER — Boiler Manual
28 
Check for gas leaks
"EFORESTARTINGTHEBOILERANDDURINGINITIALOPERATION
use a leak detector or smell near the floor and around
THEBOILERFORGASODORANTORANYUNUSUALODOR2EMOVE
BOILERJACKETDOORANDSMELLTHEINTERIOROFTHEBOILER
jacket.
$ONOTPROCEEDWITHSTARTUPIFTHEREISANY
INDICATIONOFAGASLEAK2EPAIRANYLEAKATONCE
.
$/./4ADJUSTORATTEMPTTOMEASUREGASVALVEOUT-
LETPRESSURE.
4HEGASVALVEISFACTORYSETFORTHECORRECT
OUTLETPRESSURE4HISSETTINGISSUITABLEFORNATURALGAS
ANDPROPANEREQUIRINGNOlELDADJUSTMENT!TTEMPTING
to alter or measure the gas valve outlet pressure could
result in damage to the valve, causing potential severe
personal injury, death or substantial property damage.
0ROPANEBOILERSONLY — Your propane supplier mixes
an odorant with the propane to make its presence de-
TECTABLE)NSOMEINSTANCESTHEODORANTCANFADEAND
THEGAS MAY NOLONGERHAVEAN ODOR"EFORESTARTUP
ANDPERIODICALLYTHEREAFTERHAVETHEPROPANESUPPLIER
VERIFYTHECORRECTODORANTLEVELINTHEGAS