Baxi LUNA DUO-TEC 60 GA User manual

en CONDENSING GAS FIRED WALL MOUNTED COMBINATION BOILER
Installation instructions for the installer
fr CHAUDIÈRE MURALE À GAZ À CONDENSATION À DEUX SERVICES
Notice d'installation pour l'installateur
LUNA DUO-TEC 60 GA
LUNA DUO-TEC 1.48 GA
Manufactured by:
Baxi N.A.
2201 Dwyer Avenue, Utica, NY 13501
Tel. [phone]
www.baxiboilers.com
PN 240012485 REV C [06/30/2019]

2
240012485 REV C [06/30/2019]
INSTALLER Section (en)
PHYSICAL DATA.....................................................................................................................................................................4
QUALIFIED INSTALLER / SERVICE TECHNICIAN...... 6
USER........................................................................................................................................................................................6
SAFETY INFORMATION........................................................................................................................................................6
2 - INTRODUCTION ................................................................................................................................................................8
3 - COMPONENT LISTING - 1.48 GA....................................................................................................................................9
3 - COMPONENT LISTING - 60GA......................................................................................................................................10
4 - LOCATING BOILER......................................................................................................................................11
4.1 BOILER LOCATION CONSIDERATIONS.......... 11
4.2 CLEARANCES..........................................................................................................................................................12
4.3 WALL MOUNTING.....................................................................................................................................................13
5 - HYDRONIC PIPING.........................................................................................................................................................14
5.1 GENERAL...................................................................................................................................................................14
5.2 SPECIAL CONDITIONS............................................................................................................................................15
5.3 SAFETY RELIEF VALVE...........................................................................................................................................15
5.4 TRIM PIPING..............................................................................................................................................................16
5.5 SYSTEM PIPING.......................................................................................................................................................16
5.6 EXTERNAL OPTIONAL LOW WATER CUT OFF 18
5.7 MANUFACTURER RECOMMENDATION - STRAINER 19
5.8 CENTRAL HEATING SYSTEM.................................................................................................................................19
5.9 DOMESTIC HOT WATER MODE.............................................................................................................................20
5.10 FROST PROTECTION MODE................................................................................................................................20
5.11 PUMP PROTECTION..............................................................................................................................................20
6 - COMBUSTION AIR AND VENT PIPING........................................................................................................................21
6.1 GENERAL...................................................................................................................................................................21
6.2 REMOVAL OF EXISTING BOILER FROM COMMON VENT SYSTEM 22
6.3 DEFINITIONS.............................................................................................................................................................22
6.4APPROVED VENTING MATERIALS .......................................................................................................................23
6.5 VENT TERMINATION................................................................................................................................................23
6.6 COAXIAL VENTING INSTRUCTIONS.....................................................................................................................24
6.7 COAXIAL VENT SCREW PLACEMENT - SEE FIGURE 6-6 24
6.8 TWIN PIPE SYSTEMS..............................................................................................................................................26
6.9 SECURING TWIN PIPE POLYPROPYLENE VENTING 27
6.10 FLEXIBLE VENT SYSTEM ...................................................................................................................................30
6.11 CONDENSATE PIPING...........................................................................................................................................32
7 - GAS SUPPLY PIPING......................................................................................................................................................33
7.1 GENERAL...................................................................................................................................................................33
7.2 LEAK CHECK GAS PIPING......................................................................................................................................34
7.3 GAS ORIFICE - 9.0 MM ( NATURAL & LP)..............................................................................................................34
8 - ELECTRICAL CONNECTIONS ......................................................................................................................................35
8.1 GENERAL...................................................................................................................................................................35
8.2 INSTALL ROOM END SWITCH................................................................................................................................35
8.3 ELECTRICAL CONNECTIONS ................................................................................................................................35
8.4ACCESS TO CONNECTION BLOCK.......................................................................................................................36
8.5 MAIN SUPPLY CONNECTION.................................................................................................................................36
8.6 INSTALL ROOM END SWITCH................................................................................................................................37
8.7 OPTIONAL ELECTRICAL CONNECTIONS............................................................................................................37
8.8 INDIRECT STORAGE TANK.....................................................................................................................................38
8.9 MANAGEMENT OF 0-10V INPUT..............................................................................................................................38
WIRING DIAGRAM - MODEL 1.48 GA..........................................................................................................................39
WIRING DIAGRAM - MODEL 60 GA.............................................................................................................................40
9 START UP PROCEDURE..................................................................................................................................................41
9.1 SYSTEM DESIGN PRESSURE: (COLD) SHOULD BE SET TO (1.0-1.5) BAR......................................................41
9.2 CENTRAL HEATING SYSTEM CONNECTIONS.....................................................................................................41
9.3 SYSTEM START UP..................................................................................................................................................42
9.4 FILL CONDENSATE TRAP WITH WATER..............................................................................................................42
9.5 CONTROL PANEL.....................................................................................................................................................43
9.6 PRIOR TO COMMISSIONING:.................................................................................................................................44
9.7 COMMISSIONING FOR THE FIRST TIME:.............................................................................................................44
9.8AUTOMATIC CALIBRATION FUNCTION................................................................................................................44
9.9 MANUAL CALIBRATION FUNCTION:.....................................................................................................................45
9.6 COMMISSIONING.....................................................................................................................................................45
9.10 DE-AERATION FUNCTION.....................................................................................................................................45
9.11 COMMISSION SET UP (GAS) - CHANGING THE TYPE OF GAS......................................................................45
9.12 CHIMNEY SWEEP FUNCTION (CO2ADJUST)......................................................................................................46
9.13 COMBUSTION ADJUSTMENT FUNCTION (CO2%).............................................................................................46
CONTENT

3240012485 REV C [06/30/2019]
INSTALLER Section (en)
9.14 CHECK FIRING RATE........................................................................................................................................................ 46
9.15 PARAMETER SETTINGS .................................................................................................................................................. 47
9.16 DESCRIPTION OF PARAMETERS: FACTORY SETTINGS ..........................................................................................47
9.17 ADJUSTING MAXIMUM HEATING POWER......................................................................................................................49
10 - OPERATING INSTRUCTIONS................................................................................................................................................. 50
10.1 TESTING FOR GAS LEAKS AND PURGING THE GAS SUPPLY...................................................................................50
10.2 BOILER OPERATION......................................................................................................................................................... 50
10.3 CENTRAL HEATING MODE.............................................................................................................................................. 50
10.4 DOMESTIC HOT WATER MODE...................................................................................................................................... 50
10.5 FROST PROTECTION....................................................................................................................................................... 50
10.6 PUMP................................................................................................................................................................................... 50
10.7 LOW WATER PRESSURE SENSOR (INTERNAL) .........................................................................................................50
11 - GENERAL MAINTENANCE AND CLEANING ....................................................................................................................... 51
11.1 BEGINNING OF EACH HEATING SEASON......................................................................................................................51
11.2 MAINTENANCE AND ROUTINE SERVICING...................................................................................................................52
11.3 COMPONENT REPLACEMENTAND CLEANING.............................................................................................................53
11.5 DRAINING THE HEATING CIRCUIT................................................................................................................................. 53
11.6 HYDRAULIC UNIT (DHW).................................................................................................................................................. 54
11.7 CLEANING THE COLD WATER FILTER............................................................................................................................54
11.8 FINAL COMMISSIONING................................................................................................................................................... 54
11.9 FINALASSEMBLY.............................................................................................................................................................. 54
11.10 USER INFORMATION...................................................................................................................................................... 54
11.11 SAFETY FLUE THERMOSTAT -
DO NOT DISABLE THIS SAFETY DEVICE..................................................................55
11.13 REPLACEMENT PARTS .................................................................................................................................................. 55
12 - TECHNICAL DATA ................................................................................................................................................................... 56
12.1 RATINGS AND CAPACITY................................................................................................................................................. 56
12.3 DOMESTIC HOT WATER SPECIFICATIONS....................................................................................................................56
12.2 HIGH ALTITUDE RATINGS AND CAPACITY........................................................................................................... ........57
12.4 HIGH ALTITUDE CHART................................................................................................................................................... 57
13 - TROUBLE SHOOTING............................................................................................................................................................. 58
13.1 ERROR MESSAGES AND RESETTING THE BOILER.....................................................................................................58
13.2ANOMALIES TABLE FOR THE INSTALLER - USE THIS TABLE TO REPORT THEANOMALY VALUES............ 60
14 - GLOSSARY ............................................................................................................................................................................... 61
CONTENTS (FR)......................................................................................................................................................................63

4
240012485 REV C [06/30/2019]
INSTALLER Section (en)
Dimensions
Vent
Connector
Combustion
Air
Front View
All Models
Top View
All Models
1.48 GA
HEAT ONLY
Bottom View
Dimensions
60 GA COMBI
Bottom View
Dimensions








PHYSICAL DATA
D
C
E IHGF
B
A
DE IG
C

B


B
DIMENSIONS 1.48 GA / 60GA
Height 30 " [763 mm]
Width 17  " [450 mm]
Depth 21  [571 mm]
Condensate Trap Connection
3/4" [19.1 mm] NPT
System Supply 1” [25.4 mm] NPT
DHW Outlet 3/4” [19.1 mm] NPT
Gas Connection 3/4” [19.1 mm] NPT
DHW (Cold Water) Inlet 3/4” [19.1 mm] NPT
System Return 1” [25.4 mm] NPT
Boiler Filling Connection External to Boiler
Primary Water Content 1 gal [4.73 L]
A
C
D
E
F
G
H
I
J
B

5240012485 REV C [06/30/2019]
INSTALLER Section (en)
Central Heating (Sealed System) 1.48 GA/ 60 GA
Heat Exchanger Max Allowable Working Pressure 50 psi [3.45 bar]
Max System Pressure 30.00 psi [2.06 bar]
Min System Pressure 7.25 psi [0.50 bar]
Max System Temperature 176°F [80°C]
Pressure Relief Valve Setting 30.00 psi [2.11 bar]
Expansion TankMinimum Size
(pre-charge press.) 2.2 gal at 11.6 psi [10.0 L at 0.8 bar]
Recommended System Pressure (cold) 21.7 psi [1.5 bar]
Domestic Hot Water (Sealed System) 60 GA
Max Inlet Water Pressure 116 psi [8 bar]
Min Inlet Water Pressure 2.9 psi [0.2 bar]
Min DHW Flow Rate 0.55 gpm [2.50 L/min]
Max DHW Temperature 140°F [60° C]
DHW Water Content 0.10 gal [0.37 L]
When boiler is operating at maximum operating temperature, providing heating with all heat emitters operating, pressure gauge

Available Pump Head For Central Heating


QWater Flow Rate Min Minimum speed of modulation
HHead Max Maximum speed of modulation

6
240012485 REV C [06/30/2019]
INSTALLER Section (en)
This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this
symbol to avoid possible injury or death.
HAZARD DEFINITIONS

DANGER
Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
!
NOTICE
Indicates information which should be followed to ensure proper installation and operation.
QUALIFIED INSTALLER / SERVICE TECHNICIAN
Read all instructions in this manual, and the Boiler Venting section, before installation, servicing and maintenance. Perform steps in
the order given.
USER

Refer to User's Information Manual for your reference.

After the comissioning make sure you are advised, and demostrated if necessary, of all important points as described in section 2:
"OPERATING THE BOILER" in User Manual.
SAFETY INFORMATION

important information concerning the product.
STATE/FEDERAL REGULATIONS PERMIT THE INSTALLATION OF THIS PRODUCT ONLY BY AUTHORIZED GAS
CONTRACTORS. HOWEVER, BAXI ADVISES THAT ONLY CONTRACTORS TRAINED IN THE SPECIFIC DETAILS OF THIS
BAXI PRODUCT SHALL UNDERTAKE INSTALLATION.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury
!
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
!

7240012485 REV C [06/30/2019]
INSTALLER Section (en)
Hot Water Can Scald!
Water heated to temperature for clothes washing,
dish washing and other sanitizing needs can scald
and cause permanent injury.

handicapped persons are more likely to be
permanently injured by hot water. Never leave
them unattended in bathtub or shower. Never
allow small children to use a hot water tap or draw
their own bath.

above description, or if state laws or local codes

taps, you must take special precautions:
• Use lowest possible temperature setting.
• Install some type of tempering device, such
as an automatic mixing valve, at hot water
tap or water heater. Automatic mixing valve
must be selected and installed according
to manufacturer's recommendations and
instructions.
• Water passing out of drain valves may be
extremely hot. To avoid injury:
• Make sure all connections are tight.
• 
Water
Temperature
Seng
1st Degree Burn
Exposure Time For
An Adult
2nd and 3rd Degree Burn
Exposure Time For An
Adult
120° F 1 minute 5 minutes
130° F 5 seconds 30 seconds
140° F 2 seconds 5 seconds
150° F 1 second 1.5 seconds
160° F Instantaneous 0.5 seconds
Note: Warning for Infants, Children, and Elderly: Great care must
be taken when exposing the aforementioned groups to warm or
hot water as they can be badly burned in exposure times less than
half of the time for an adult.
SAVE THESE INSTRUCTIONS
WARNING
Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious

!
WARNING
Do not tamper with or use this boiler for any purpose other than its intended use. Failure to follow these
instructions could result in death or serious injury. Use only manufacturer recommended parts and accessories.
!
CAUTION
Laceration, burn hazard. Metal edges and parts may have sharp edges and/or may be hot. Use appropriate

Failure to follow these instructions could result in minor or moderate injury.
!

8
240012485 REV C [06/30/2019]
INSTALLER Section (en)
2.5 Designated Use
• 60 GA provide both central heating and domestic hot water.
• 1.48 GA central heating only.
• Indoor installation.
• 
• Direct vent boiler.
• 
2.6 The unit MUST NOT:
• Directly heat potable water from the central heat circuit. Indirect heating is acceptable.
• Heat water with non-hydronic heating system chemicals present (example, swimming pool water).
• Toxic chemicals, such as those used for boiler treatment, shall not be introduced into potable water.
• Exceed 43 psig (2.96 bar) maximum system pressure, or drop below minimum system pressure 7.25 psig (.50 bar)
• Exceed 176°F (80°C) system design temperature.
2.7 Operational Features
• 1.48 GA Modulates input to provide CH Turndown 5.5:1.
• 60 GA Modulates input to provide CH Turndown 5.5:1, DHW Turndown 7:1.
• Maximum output available for domestic hot water:
60 GA - 180,000 btu/h (53 kW), capable of providing 5.0 (U.S.) gpm (18.9 liters/min) with temperature rise of 70°F/39°C.
• 󰀨
• Optional Outdoor Temperature Reset.
• Heat exchanger over heat protection.
• Boiler operating at maximum operating temperature, providing heat, pressure gauge should not indicate more than

2 - INTRODUCTION
2.1 Installation shall conform to requirements of authority having jurisdiction or in absence of such
requirements:
UNITED STATES
• National Fuel Gas Code, ANSI Z223.1/NFPA 54 .
• National Electrical Code, NFPA 70.
CANADA
• Natural Gas and Propane Installation Code, CAN/CSA B149.1.
• Canadian Electrical Code, Part I, Safety Standard for Electrical Installations, CSA C22.1
2.2 Where required by authority having jurisdiction, installation shall conform to Standard for
Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
󰀨
2.3 Requirements for Commonwealth of Massachusetts:
Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited to:

2.4 Manufacturer recommends use of Carbon Monoxide monitor may be requirement of local
jurisdiction.

9240012485 REV C [06/30/2019]
INSTALLER Section (en)
ITEM
NO.
1Pump
2Boiler Drain Tap
3󰀨
4Gas Valve
5
NTC Heating sensor (Flow/Return)
QTY 2, (1 Shown for clarity)
6Water Safety Thermostat
7Flue Sensor
8Coaxial Connector
9Heat Exchanger Temperature
Sensor
10 Heat Exchanger
11 Burner Door Temperature
Sensor
12 Burner (not shown)
13 Ignition Electrode
14 Flame Detection Electrode
15 Air/Gas Blend Manifold
16 Air Purge
17 Venturi
18 Silencer
19 Fan
2
1
8
7
6
5
13
9
14
4
12
19
15
17
10
16
11
18
3
3 - COMPONENT LISTING - 1.48 GA

10
240012485 REV C [06/30/2019]
INSTALLER Section (en)
ITEM
NO. 60 GA
1Pump
2Flow Sensor
3DHW Priority Sensor
4DHW Heat Exchanger
5Gas Valve
6NTC DHW Sensor
7󰀨
83-Way Valve with Motor
9
NTC Heating sensor (Flow/Return)
QTY 2, (1 Shown for clarity)
10 Water Safety Thermostat
11 Flue Sensor
12 Coaxial Connector
13 Heat Exchanger Temperature
Sensor
14 Heat Exchanger
15 Burner Door Temperature
Sensor
16 Burner (not shown)
17 Ignition Electrode
18 Flame Detection Electrode
19 Air/Gas Manifold
20 Air Purge
21 Venturi
22 Silencer
23 Fan
3
1
26
12
4
11
10
9
8
18
13
19
5
17
21
20
23
14
7
15
16
22
3 - COMPONENT LISTING - 60GA

11 240012485 REV C [06/30/2019]
INSTALLER Section (en)
4.1 Boiler Location Considerations
• 
• Approved for installation in closets or alcove provided it is correctly designed for that purpose and minimum clearances are
met.
• Protect gas ignition system components from water (dripping, spraying, rain, etc.) during operation and service (circulator
replacement, condensate trap, control replacement, etc.).
• Access to outdoors to meet minimum and maximum pipe lengths for combustion air and vent piping. See section 6.
• Disposal of condensate. See section 6.
• Drainage of water (or water - antifreeze solution) during boiler service or from safety relief valve discharge. See section 5.
• Access to system water piping, gas supply, and electrical service. See sections 5, 7 and 8.
• Clearances to combustible materials and service clearances. See Table 1 and Figures pg. 12.
• 
• Room-sealed boiler installed in a room containing bath or shower shall be installed so person using bath or shower cannot
touch any electrical switch or boiler control utilizing line voltage electricity.
• Multiple Boilers can be wall mounted, placed side by side, or back to back.
• Observe service clearances in all installations.
• 
compartment.
WARNING
FIRE HAZARD! DO NOT INSTALL ON CARPETING. Failure to follow these instructions could result in
death or serious injury.
!
4 - LOCATING BOILER

12
240012485 REV C [06/30/2019]
INSTALLER Section (en)
4.2 Clearances
NOTE:
protection clearances.
TABLE 1: BOILER CLEARANCES
Dimension Combustible
Materials (1) Manufacturer
Recommended for Service(1)(2)
Top 0" (0 cm) 8-5/8" (220 mm)
Left Side 1-3/4" (45 mm) 1-3/4" (45 mm)
Right Side 1-3/4" (45 mm) 1-3/4" (45 mm)
Front 0" (0 mm) 17-3/4"(450 mm)
Back 0" (0 mm) 0" (0 mm)
Bottom 0" (0 mm) *9-13/16" (250 mm)
Combustion Air/Vent piping 0" (0 mm) 6" (160 mm)
(1) Required distances measured from boiler jacket.
(2) Service, proper operation clearance recommendation.
* Allowance for piping at the bottom of boiler not included.
Minimum Clearance
17 ¾ in. [450 mm ]
From Front of Boiler
13.58 in /
345.00 mm
1   in
[45 mm]
17  in
[450 mm]
8 ⅝in [220 mm]
9 in [250 mm]
30 in
[763 mm]
1.48 GA & 60 GA
21½in
[571.5 mm]
1   in
[45 mm]
Left Side View of
Boiler Front View of
Boiler
Service Clearances
        
[45 mm]

Top View
Back
Closet Installation
0 in /0 mm between Back of Unit and wall
        
[45 mm]
1
[45 mm]
1       
[45 mm]
[450 mm]
Front View of Boiler
0in
[0 mm]
0in
[0 mm]
Top View
0 in
[0 mm]
0 in
[0 mm]
Combustible Clearances

13 240012485 REV C [06/30/2019]
INSTALLER Section (en)
4.3 Wall Mounting
1. 
2. Tape template to the wall. Ensure template is level and upright. Mark position of holes for boiler mounting bracket and
plumbing connections.
3. 
4. 

5. : 5 " [135 mm] diameter
6. 
7. Mount boiler on wall using wall mounting bracket included with unit.
8. Adjust the position of the boiler verify it is level and plumb.
FIGURE 4-1 Wall Mount Bracket
(Included)
Center brackets. Avoid
overhang on sides of wall
mount bracket.
Use four (4) predrilled
holes for mounting bracket
to wall
NOTICE

damage to the boiler.


CAUTION
Boiler weight exceeds 140 pounds (63.5 kg). Do not lift boiler onto wall without assistance
!

14
240012485 REV C [06/30/2019]
INSTALLER Section (en)
5.1 General
• 
• Install piping in accordance with authority having jurisdiction.
• Support system piping and safety relief valve discharge piping. Boiler's internal piping and wall mount bracket can be
damaged if subjected to excessive weight.
NOTICE
The intended use of the internal heat exchanger pump is a boiler loop. Do not use as a primary system pump.
• 
pump compensates for pressure drop through boiler internal piping and heat exchanger.
• 
• If oil is present in system water, use approved detergent to wash system.
• 
• Manufacturer recommends installation of magnetic dirt separator in the hydronic system where there are cast iron or steel
󰀩
󰀩
premature wear.
• 
• Flush system until water runs clean and piping is free of sediment.
• 
them to properly clean the system.
• When purging installations that include standing iron radiators and systems with manual vents at high points, start with

furthest air vent.
• Install a basket strainer if large amounts of sediment is present. Keep basket clear of sediment build up.
• Manufacturer recommends a water treatment product be used for sediment removal.
• Ensure piping in the heating system has an oxygen barrier.
• 
gasket connection when using a single wall polypropylene vent system.
5 - HYDRONIC PIPING
WARNING
• Poison hazard. Ethylene glycol is toxic. Do not use ethylene glycol.
• Never use automotive or standard glycol antifreeze, even ethylene glycol made for hydronic systems.
• Ethylene glycol can attack gaskets and seals used in hydronic systems.
• Do not use petroleum based cleaning or sealing compounds boiler system.
• 
• 
closed water heating system.
• 
• 
!
WARNING
󰀨
testing of that system at test pressures in excess of 1/2 psi (3.40 kPa - 34.47 mbar).
󰀨

Install boiler so that gas ignition system components are protected from water (dripping, spraying,rain, etc.)
during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.).
!
NOTICE
Boiler rated at 50 psig (345 kPa) maximum allowable working pressure. Boiler provided with 30 psig (206 kPa)
safety relief valve.
When installing safety relief valve it must be installed in a vertical position with spindle at top.
System pressure above 43 psi [2.96 bar] WILL result in boiler shutting down.

15 240012485 REV C [06/30/2019]
INSTALLER Section (en)
FIGURE 5-1 Safety Relief Valve Discharge Piping
5.3 Safety Relief Valve
• 
• Install safety relief valve with spindle in vertical position.
• 󰀨
• Install discharge piping from safety relief valve. Do not use plastic pipe.
• Use ¾" or larger pipe.
• Use pipe suitable for temperatures of 375°F (191°C) or greater. Do not use plastic pipe on safety relief valve.
• Individual boiler discharge piping shall be independent of other discharge piping.
• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve
capacity stated on rating plate.
• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.
• Install union, if used, close to safety relief valve outlet.
• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).
Check Local Codes For
Maximum Distance To Floor
Safety Relief Valve
5.2 Special Conditions
• 
use with closed water heating system. Do not use automotive or ethylene glycol.
• 
provided in boiler.
• Boiler used in connection with refrigeration system. Install piping in parallel with boiler, with appropriate valves to prevent
chilled medium from entering boiler.
• 
control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.
Do not use
plastic pipe see
Warning Above
WARNING
Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install
discharge piping per these instructions.
!
NOTICE
Do not expose boiler and condensate piping to freezing temperatures.
WARNING
Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Use pipe
suitable for temperatures of 375°F (191°C) or greater. DO NOT use plastic pipe.
!
Field Sourced
(elbow and nipple)

16
240012485 REV C [06/30/2019]
INSTALLER Section (en)
5.4 Trim Piping
• Temperature - Pressure Gauge. Install temperature pressure gauge in near boiler piping.
• Some boiler models may have integral drain valve located inside jacket directly underneath pump. Install provided external

5.5 System Piping
• Ensure plugs are removed from boiler water connections.
• 
• 
• Single boiler system. See Figures 5-2, 5-6, for general guidance. Additional considerations:
A. Boiler control only supports integrated pump. Installer responsible for integration of multiple central heating pumps

B. Boiler control allows domestic hot water prioritization. Function could be lost if central heating pump is not directly
connected to control system.
• 
• 
WARNING
Burn and scald hazard. Verify all plastic plugs are removed from boiler connections. Failure to follow these
instructions could result in death or serious injury.
!
• 
Figures 5-1 .
• Verify all drain valves are closed.

17 240012485 REV C [06/30/2019]
INSTALLER Section (en)
FIGURE 5-2 - Piping Diagram - LWCO Location
󰀨
(See Figure 5-5 for detail)
Air Vent
Supply
Position LWCOAbove
Top of Boiler
1DO NOT PLACE ISOLATION VALVE
BEFORE TEE OR LWCO.
1
1



18
240012485 REV C [06/30/2019]
INSTALLER Section (en)
FIGURE 5-4 - Low Water Cuto󰀨 - Detail
5.6 External Optional Low Water Cut O󰀨
󰀨

Follow LWCO manufacturer installation instructions for type of LWCO selected in addition to these instructions.
LWCO shall be 120V/60HZ control and dry contacts sized for load being connected. Wire control to boiler. See Figure 5-3.


• Locate LWCO sensing device in the supply piping, above the minimum height of boiler. See Figure 5-2, Piping Diagram.
• Position control in HORIZONTAL piping to assure proper boiler protection (upright or 90° rotation).
• For proper operation, sensing element of the LWCO control shall be positioned in the tee to sense the main water stream.
Maintain minimum 1/4” spacing from pipe walls. Element shall NOT contact the rear, or side walls of the tee. See Figure 5-4.
• Install an air vent using a tee to avoid nuisance shutdowns.
• Apply small amount of pipe sealant to threaded connections.
• Arrange piping to prevent water dripping onto boiler.
• 󰀨
󰀨
Electrical Conduit
J-Box
120 V/60 HZ
Conduit or Power
Supply cord
(Polarized)
L1
N
G
GND
L1
N
GND
BLK
WHT
120 V/60 HZ Socket
(Polarized) 120 V/60 HZ
Cord Set From Boiler
N.O
FIGURE 5-3 - LWCO Wiring Diagram
NO
YES
NO

19 240012485 REV C [06/30/2019]
INSTALLER Section (en)
5.7 Manufacturer Recommendation - Strainer
Manufacturer Recommendation

any sedimentation and debris from your water supply piping from entering the boiler. Debris carried from the water supply will clog

Locate the strainer as close to the boiler as possible and place on DHW (domestic hot water) inlet connection located at bottom
of the boiler.
Potable water
IN
Potable water
OUT
STRAINER
5.8 Central Heating System

(80° C), take pump head, expansion tank size, mean radiator temperature, etc. into account.
Boiler is supplied with the following components: Pressure relief valve - 30.0 psi (2.1 bar). Boiler internal pressure switch will shut
󰀨
Pressure gauge - to indicate the system pressure to be maintained.
By-pass 

BOILER
FIGURE 5-5 - Use of Strainer

20
240012485 REV C [06/30/2019]
INSTALLER Section (en)
FIGURE 5-6 Primary Secondary Piping
5.9 Domestic Hot Water Mode
WARNING
Burn, Scald Hazard! Water temperature over 125°F (51°C) can cause severe burns and scalding. See User's
Manual before setting water temperature. Failure to follow these instructions could result in death or serious
injury.
!
1.48 GA & 60 GA with indirect tank
• 
• 
to circulate the primary water through the DHW plate heat exchanger. (60 GA only)
• Combustion fan will then come on and begin to run at ignition speed.
• 

chamber and send a signal to the control board.
• Temperature sensors will send a signal to the control board allowing the control board to increase/ decrease the speed of
the fan. The combustion fan will in turn modulate the gas rate accordingly.
• When the domestic hot water demand ceases the burner will extinguish, unless there is a demand for central heating.
5.10 Frost Protection Mode
Frost protection mode is integrated into the appliance when power is supplied, regardless if boiler is in "OFF" or "ON" mode. If the

5.11 Pump Protection
Pump will automatically operate for 1 minute in every 24 hours to prevent seizing.
CH/System
Pump
ASME Relief
Valve
Purge Valve
Magnetic
Dirt
Separator
112” (305MM) MAXIMUM SEPARATION
Note
1
Cold Water
Supply
BOILER