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SYNC-I-O Rev M.indd

1. 37 PVC CPVC Vent Piping Materials 17 Gas Valve Replacement 37 PVC CPVC Air Intake Vent Connections 18 7 FIELD WIRING Air Inlet Pipe 18 Line Voltage Connections 38 Requirements for Installation in Canada 19 Low Voltage Connections 39 Installing Vent and Air 19 Wiring of the 40 Stainless Steel Vent and Air Piping 20 8 CONDENSATE DISPOSAL Min Max Combustion Air amp Vent Piping Lengths 21 Condensate 42 Vent and Air Piping 21 9 STARTUP 43 48 3 SIDEWALL DIRECT VENTING 10 OPERATING INFORMATION Vent Air Termination Sidewall 22 25 E E EN E E 49 51 Determine 22 24 Cascade NET E EEE 51 52 Prepare Wall Penetrations 24 Sequence of Operation 53 Termination and Fi
2. 6 152 MM MINIMUM ABOVE ROOF SNOW LINE VENT OUTLET 36 914 MM MINIMUM ABOVE AIR INLET 5 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment Prepare roof penetrations 1 Air pipe penetration a Cuta hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter 2 Vent pipe penetration a Cutahole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 7 inch 178 mm hole for 6 inch 152 mm vent pipe 8 inch 203 mm hole for 7 inch 178 mm vent pipe b Insert a galvanized metal thimble in the vent pipe hole when required by local codes 3 Space the air and vent holes to provide the minimum spacing shown in FIG s 4 1 and 4 2 4 Follow all local codes for isolation of vent pipe when passing through floors ceilings and roofs 5 Provide flashing and sealing boots sized for the vent pipe and air pipe SYNG CONDENSING BOILER Installation amp Operation Manual Vertical direct venting continue Multiple vent air terminations 1 When terminating multiple SYNC boilers terminate each vent air connection as described in this manual FIG 4 3 Terminate all vent pipes at the same height A WARNING and all air pipes
3. Fill condensate trap with water 1 Remove the PVC cap retaining screw from the PVC cap FIG 9 1 2 Remove the 2 inch PVC cap with the switch located at the top of the trap FIG 9 1 3 Fill with fresh water until the water begins to pour out of the drain 4 Replace the cap Press the cap onto the trap until the cap makes contact with the drain 5 Replace the retaining screw The condensate trap FIG 9 1 must be A WARNING filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death Start up continued Final checks before starting the boiler LI Read the SYNC Service Manual to familiarize yourself with SMART TOUCH control module operation Read this manual page 46 for proper steps to start boiler LI Verify the boiler and system full of water and all system components are correctly set for operation LI Verify the preparation procedures of Section 9 pages 43 and 44 have been completed Fill the vent condensate trap with water removing the retaining screw in order to remove the 2 inch 50 8 mm PVC cap with the switch located at the top of the trap Replace the cap Press the cap onto the trap until the cap makes contact with the drain Replace the retaining screw Verify electrical connections are correct and securely attached Q Inspect vent piping and air pip
4. If flooding is possible elevate the boiler sufficiently to prevent water from reaching the boiler Vent and air piping The SYNC requires a special vent system designed for pressurized venting The boiler is to be used for either direct vent installation or for installation using indoor combustion air When room air is considered see Section 4 Vertical Direct Venting Note prevention of combustion air contamination below when considering vent air termination Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall unless otherwise specified You may use any of the vent air piping methods covered in this manual Do not attempt to install the SYNC using any other means Be 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 given in this manual Prevent combustion air contamination Install air inlet piping for the SYNC as described in this manual Do not terminate vent air in locations that can allow contamination of combustion air Refer to Table 1A page 10 for products and areas which may cause contaminated combustion air Ensure that the combustion air will not contain any of the contaminants in Table 1A page 10 Contaminated combustion air will damage the boiler resulting in possible severe perso
5. adjust the parameter press the or buttons to change the value being displayed 5 Make the correct adjustments and then press the APPLY button 6 Once all the parameters have been adjusted press the BACK button This will return you to the Setup Menu 7 Press the SAVE button to program all controls Note The SAVE button must be pressed to ensure proper programming of the controls Failure to press the SAVE button will require all changes to be reprogrammed 10 Operating information General How the boiler operates The SYNC uses advanced stainless steel heat exchangers and electronic control modules that allow fully condensing operation The blowers pull in air and push flue products out of the boiler through the heat exchangers and flue piping The control modules regulate blower speed to control the boiler firing rate The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow How the control modules operate The SYNC boiler is equipped with two 2 SMART TOUCH control modules The control modules work in synchronization to meet the heat demand of the system The SMART TOUCH control modules receive input from boiler sensors and external inputs The control modules activate and control the blowers and gas valves to regulate heat input and switches the boiler Hot Water Generator HW and system pumps on and off as needed The user programs the control modules to
6. e Check for leaks water gas flue condensate e Verify flue and air lines in good condition and sealed tight e Check system water pressure system piping expansion tank Check control settings Check ignition and flame sense electrodes sand off any deposits clean and reposition Check wiring and connections e Perform start up checkout performance verification per Section 9 Flame inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F 30 above return water temperature e Test low water flow conditions reference the SYNC Service Manual If combustion or performance indicate need Clean heat exchanger e Remove and clean burner using compressed air only e Clean the blower wheel Installation amp Operation Manual Owner maintenance see the SYNC User s Information Manual for Monthly Every 6 months End of season months instructions e Check boiler area e Check pressure temperature gauge e Check vent piping e Check air piping e Check air and vent termination screens e Check relief valve e Check condensate drain system e Check automatic air vents e Test low water cutoff e Reset button low water cutoff e Check boiler piping gas and water for leaks e Operate relief valve e Shut boiler down unless boiler used for domestic hot water 57
7. 2 Mountthe sensor on an exterior wall shielded from direct sunlight or flow of heat or cooling from other sources 3 Route sensor wires through a knockout at the rear of the boiler see FIG 7 2 SYNC Installation amp Operation Manual Hot Water Generator thermostat HW 1 Connect the HW tank thermostat to the Tank Thermostat terminals on the connection board FIG 7 3 Hot Water Generator HW tank sensor 1 By installing a HW tank sensor the SMART TOUCH control can perform the tank thermostat function The SMART TOUCH control automatically detects the presence of this sensor and generates a HW call for heat when the tank temperature drops 6 F 3 C below the tank set point and finishes the call for heat when the tank temperature reaches the tank set point 2 ATST2032 sensor MUST be used with any indirect tank Failure to use the correct sensor will result in the tank temperature being either above or below the set point Connect the correct sensor to the Tank Sensor terminals see FIG 7 3 Louver proving switch 1 Louvers are used to provide combustion air for the room air option louver proving switch should be installed on the appropriate terminals and verified prior to operation see FIG 7 3 Flow switch field supplied 1 Flow switches are designed to prevent a no flow situation 2 Aflow switch may be used to guarantee flow through the boiler before allowing it to fire When used the
8. 4 The SYNC must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service 5 Ifa new boiler will replace an existing boiler check for and correct system problems such as System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits Incorrectly sized expansion tank Lack of freeze protection in boiler water causing system and boiler to freeze and leak SYNC CONDENSING BOILER Installation amp Operation Manual A WARNING This appliance is certified as an indoor appliance Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100 F Do not install the appliance where the relative humidity may exceed 9396 Do not install the appliance where condensation may form on the inside or outside of the appliance or where condensation may fall onto the appliance Failure to install the appliance indoors could result in severe personal injury death or substantial property damage This appliance requires a special ventin A WARNING PP q system Use only the vent materials primer and cement specified in this manual to make the vent connections Failure to follow this warning could result in fire personal injury or death Closet and alcove installations A closet is any room the boiler is installed in which is less t
9. Installation amp Operation Manual 1 1 Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature A WARNING i i shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage The boiler should be inspected annually only by a qualified service technician In addition the maintenance A WARNING and care of the boiler designated in Table 11A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as A WARNING oM CM noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems Figure 11 1 Condensate Trap 1 Inspect any problems reported by the owner and correct before proceeding 2 PVC CAP WITH NC BLOCKED DRAIN SWITCH Inspect boiler area Mu PVC TEE ASSEMBLY SCREW 1 Verify that boiler area is free of any combustible materials FACTORY SUPPLIED gasoline and
10. NOTICE Maximum allowed working pressure is located on the rating plate Notes m The ratings are based on standard test procedures prescribed by the United States Department of Energy ps Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 UNIT EQUIPPED FOR gt HIGH ALTITUDE 3 000 FT TO 12 000 FT a SYNC boilers require special gas venting Use only the vent materials and methods specified in the SYNC Installation and Operation Manual M Standard SYNC boilers are equipped to operate from sea level to 4 500 feet only with no adjustments The boiler will de rate by 4 for each 1 000 feet above sea level up to 4 500 feet p High altitude SYNC boilers are equipped to operate from 3 000 to 12 000 feet only with no field adjustments Figure A High Altitude Label Location The boiler will de rate by 296 for each 1 000 feet above 3 000 feet High altitude models are manufactured with a different control module for altitude operation but the operation given in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the unit zm Ratings have been confirmed by the Hydronics Section of AHRI 1 Determine boiler location Installation must comply
11. PVC CPVC Polypropylene or ABS Dryer Vent or Sealed Flexible Duct not recommended for rooftop air inlet Galvanized steel vent pipe with joints and seams sealed as specified in this section Type B double wall vent with joints and seams sealed as specified in this section AL29 4C stainless steel material to be sealed to specification of its manufacturer Plastic pipe may require an adapter not provided to transition between the air inlet connection on the appliance and the plastic air inlet pipe A WARNING Using air intake materials other than those specified can result in personal injury death or property damage NOTICE The use of double wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air Sealing of Type B double wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System a Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P ora high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric b Do not install seams of vent pipe on the bottom of horizontal runs c Secure all joints with a minimum of three 3 sheet metal screws or pop rivets Apply Aluminum Foil Duct Tape or silicone seala
12. SYSTEM CIRCULATOR r BACK FLOW PREVENTER X B e b oc St k MAKE UP WATER WATER GENERATOR CIRCULATOR TYPICAL Y STRAINER RECOMMENDED PRESSURE REDUCING TYPICAL VALVE FLOW CHECK VALVE TYPICAL EXPANSION TANK PRESSURE GAUGE UNION TYPICAL TEMPERATURE PRESSURE GAUGE 2 W EEN A zi p F lt a A 2 lt a Le P 4 Q m 2 2 HEAT EXCHANGER 1 BOILER PUMP PRESSURE RELIEF HEAT EXCHANGER 2 BOILER PUMP TO FLOOR DRAIN TYPICAL NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE System flow should always remain higher than the required flow for the boiler s when the boiler s is in operation to prevent short cycling and high limit issues EN 55 6 Gas connections Connecting gas supply piping 1 Refer to FIG 6 1 to pipe gas to the boiler a Install ground joint union for servicing when required b In Canada When using manual main shutoff valves it must be identified by the installer 2 Install sediment trap drip leg Figure 6 1 Gas Supply Piping Ensure that the high gas pressure regulator is at least 10 feet 3 m upstream of the appliance GAS SUPPLY 10 LINEAR FEET REQUIRED UNION DRIP LEG MANUAL SHUTOFF VALVE FIELD S
13. the boiler and system pumps operate constantly Below 37 F 3 C the boiler turns on Boiler and pumps turn off if boiler water temperature rises above 45 F 7 C A CAUTION This feature of the SMART TOUCH control module does not eliminate the possibility of freezing The installation must still use recognized design installation and maintenance practice to prevent freeze potential for the boiler and system SYNC ING BOILER Installation amp Operation Manual 10 Operating information Monitor external limits Connections are provided on the connection board for external limits such as flow switch and a louver proving switch The SMART TOUCH control will shut off the burner and inhibit relighting whenever any of these external limits open Run time and alarm outputs The boiler provides dry contacts for indicating when the boiler is running and when it is unable to operate Run time and cycle counting The control uses two timers to monitor the total hours of burner operation One timer monitors the time the boiler is firing under 5096 of rate The other timer monitors the time the boiler is firing over 50 rate The control uses four 4 ignition counters to monitor the amount of boiler cycles The first counter counts all ignitions of the control The second counter counts only ignition attempts that have failed The third and fourth counters are the same as the first and second respective
14. IARC has concluded Crystalline silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent airborne dust Remove the combustion chamber lining from the boiler and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediatel
15. parameter Boiler Status This line shows the current operating status of OA Shutdown The outside air has the SYNC boiler Displayed items are as follows exceeded the Outdoor Shutdown Set Point parameter vamus e The Boles walk wes SH Set Point Met The water temperature as measured by the system supply sensor has exceeded the User Set Point parameter or if the optional Outdoor Air Sensor was used the calculated set point based on the Outdoor Reset parameters On Off button Pressing this button allows the boiler to be placed in either Manual Shutdown Mode or Standby Mode respond to either a system call or a hot water generation call Standby The boiler has not received a system call or hot water generation call SH Call for Heat The boiler has received system heat Anti Cycle Delay The boiler has satisfied a system heat call but has received another system heat call SH Pump Delay The boiler has satisfied a system heat before the anti cycling time parameter has elapsed call and the boiler pumps are running for a fixed e Cascade ComError A communication error has time to remove any residual heat occurred between the Control Module 1 and Control HW Storage The boiler has received a hot water Module 2 or between the Leader and Member boilers generation call HW Pump Delay The boiler has satisfied a hot water generation call and the hot water generator pumps are r
16. FANS Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and or cause a downdraft in the venting system Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be opening a minimum of approximately 2596 Check with corrected immediately louver manufacturers for exact net free area of louvers TABLE 1B MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM Inside Air from 2 Ducts Delivered from Interior Space Opening in Opening in Outside Air from 2 Ducts Delivered from Outdoors Bottom Opening in Outside Air from 2 Openings Directly from Outdoors Outside Air from 1 Opening Directly from Outdoors in Opening in Opening in Opening in 1613 cm 1613 cm 3226 cm 3226 cm 6452 cm 6452 cm 2149 cm 325 325 650 650 1300 1300 433 750 4839 cm 2420 2420 cm 4839 9678 9678 cm 3226 Outside air openings shall directly communicate with the outdoors When combustion air is drawn from the outside through duct the net free area of each of the two openings must have twice 2 times the free area required for Outside Air 2 Openings The above requirements are for the appliance only additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances Combined in
17. LESS THAN 10 3 M 738 914 MM MIN FORCED AIR INLET BIRD SCREEN TYPICAL T 2 1 M MIN ABOVE ANY PUBLIC WALKWAY Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes Air pipe penetration a Cuta hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter Vent pipe penetration a Cuta hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 715 inch hole for 6 inch vent pipe 815 inch hole for 7 inch vent pipe Drill 3 16 diameter holes for inserting the plastic anchors into the wall For Polypropylene Only Install the vent and air intake sidewall adapters from Table 2E on page 20 into the vent plate Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate FIG 3 4B For PVC CPVC Only Install the vent and air intake piping through the wall into the vent plate openings Use RTV silicone sealant to seal the air pipe Use the cement primer listed in Table 2C on page 19 to seal the vent pipe Mount and secure the vent plate to the wall using stainless steel screws Seal all gaps between the pipes and wall Seal around the plate to the wall assuring no air gaps Assemble the vent cap to the vent plate see FIG s 3 4A and 3 4B Inse
18. LOH XVN 8 L ES N D IN 3 N aAOSg jus Sel MN TN Qo L XH SLOVINOD AM N S3 o8 dV 8L SaNNa S V VIN f Field Wiring continued Low voltage connections 1 Route all low voltage wires through the knockouts in the rear of the boiler as shown in FIG 7 2 2 Connect low voltage wiring to low voltage connection board as shown in FIG 7 3 on page 41 of this manual and the boiler wiring diagram Figure 7 2 Routing Field Wiring LOW VOLTAGE LOW VOLTAGE CONNECTION BOARD WIRING KNOCKOUTS LINE VOLTAGE WIRING KNOCKOUTS Enable 1 Connect the room thermostat or boiler enable contacts isolated contact only to terminals and W as shown in FIG 7 3 2 Ifathermostat is used install the thermostat on the inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunlight or fireplaces 3 Thermostat anticipator if applicable a If connected directly to boiler set for 0 1 amps b If connected to relays or other devices set to match total electrical power requirements of connected devices See device manufacturers specifications and thermostat instructions for details Outdoor temperature sensor 1 Connect the outdoor temperature sensor FIG 7 3 to the Outdoor Sensor terminals on the connection board to enable outdoor reset operation of the SYNC
19. SERVICE CLEARANCES Front 30 762 mm Top 24 610 mm Left Side 24 610 mm Rear 24 610 mm _ 6 152 FRONT Installation amp Operation Manual For closet installations CPVC polypropylene or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures Failure to follow this warning could result in fire personal injury or death 4 330 MM TOP VENTILATING AIR OPENING CLOSED DOOR VENTILATING AIR OPENING 6 152 MM RIGHT OF EACH OPENING 1 SQ INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ INCHES Figure 1 2 Alcove Installation Minimum Required Clearances 1 4 6 MM MINIMUM CLEARANCE AROUND HOT WATER PIPES 1 25 MM MINIMUM CLEARANCE AROUND VENT PIPES LEFT 24 610 MM REAR RECOMMENDED SERVICE CLEARANCES Front 30 762 mm Top 24 610 mm Left Side 24 610 mm Rear 24 610 mm o um AN MAMAN For alcove installations CPVC polypropylene or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures Failure to follow this warning could result in fire personal injury or death 13 330 MM TOP Ps OPEN FRONT RIGHT Installation amp Operation Manual 1 Determine boiler location continued Provide air openings to room The SYNC alone in boiler room 1 No air ventilation openings int
20. a period of time This pump delay is set at the factory to 30 seconds Ifa shorter or longer delay is desired the appropriate parameter in the control must be changed See the SYNC Service Manual for a detailed explanation of this procedure If there is an active space heating call for heat then the boiler pumps will be turned on and the HW pumps will be turned off Set HW target temperature When in the HW Mode the control will modulate to maintain the outlet temperature to a set point This set point is set at the factory to 180 F Ifa different set point 1s desired the appropriate parameter in the control must be changed See the SYNC Service manual for a detailed explanation of this procedure Set clock To program the clock access the night setback parameter by pressing the following buttons ELM The SMART TOUCH control has a built in clock that it uses for its night setback feature and for logging events This clock must be set when the boiler is installed and anytime the boiler has been powered off for more than one month Use the following procedure to set the clock gt kz 1 To set the clock press the SELECT button in the upper right hand corner of the display The date and time are displayed as Day dd mm yy hh mm Day day of the week 1 Monday 2 Tuesday etc dd date mm month yy year hh hour mm minutes 24 hour time 2 30PM 14 30 48 SYNC CONDENSING BOILER Insta
21. air elimination device on the system supply Install a drain valve at the lowest point of the system Note The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi 103 kPa This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The safety relief valve is installed at the factory and is located on the rear of the boiler Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief Pipe the discharge to a drain Provide piping that is the same size as the safety relief valve outlet Never block the outlet of the safety relief valve On any pre existing system it is good practice to install a field supplied strainer to prevent damage to the heat exchanger See the piping illustrations included in this section FIG s 5 5 and 5 6 for suggested guidelines in piping the SYNC NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes GYNG Installation amp Operation Manual CONDENSING BOILER 5 Hydronic piping continued Circulator sizing The SYNC heat exchanger does have a pressure drop which must be considered in your system design Refer to the graph in FIG 5 4 for pressure drop through the SYNC heat exchanger Near boiler piping con
22. an Existing Boiler Section on page 11 With polypropylene and stainless steel vent seal and connect all pipe and components as specified by the vent manufacturer used with PVC CPVC vent see the Installing Vent or Air Piping Section on page 19 If any of these conditions are not met the existing system must be updated or replaced for that concern Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death GYNG Installation amp Operation Manual CONDENSING BOILER 1 Determine boiler location continued When removing a boiler from existing common vent system A DANGER Do not install the SYNC into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible severe personal injury death or substantial property damage A WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation e Seal any unused openings in the common venting system p Visually inspect the venting system for proper size and horizontal pitch and
23. determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition c Test vent system Insofar as is practical close all building 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 Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any po
24. ee SLOIVLNOD INHVIV 1 m E gt x HOLIMS joe ONIAOUd u3AnO1 cool WALSAS o INIWI YNYN D NIATIINJ EH um Condensate disposal Condensate drain 1 This boiler is a high efficiency appliance that produces condensate 2 The rear of the boiler has a 1 2 inch 12 7 mm PVC union for connection of a 1 2 inch 12 7 mm PVC pipe FIG 8 1 3 Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter Condensate from the SYNC will be slightly acidic typically with a pH from 3 to 5 Install a neutralizing filter if required by local codes A Neutralizer Kit FIG 8 1 is available from the factory KIT3046 4 Install the 1 2 inch 12 7 mm PVC tee assembly shipped with the unit as shown in FIG 8 1 5 Leave the top of the 1 2 inch 12 7 mm tee OPEN This is needed as a vacuum break 6 Do not expose condensate line to freezing temperatures Figure 8 1 Condensate Disposal 1 2 12 7 mm PVC TEE ASSEMBLY FACTORY SUPPLIED FLOOR DRAIN GYNG Installation amp Operation Manual NOTICE Use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement NOTICE To allow for proper drainage on large horizontal ru
25. on page 48 along with the addition of the Flow Sensing Device section Revision C ECO C03223 reflects edits made to the high altitude section on page 6 Revision D ECO C03735 reflects edits made to the venting section removal of B149 2 along with the addition of the hydro and dirt separator Revision E ECO C04062 reflects changes to the terminology in all SYNC manuals and labels from module to heat exchanger exception contro module along with changing out dirt separator for Y strainer ECR R02455 edits made to the ceramic fiber material warning removal of the stabilitor from FIG 11 2 04057 and placing the illustrations disclaimer all the piping drawings ECR R02431 Revision F ECO C04560 reflects the addition of Modbus to the manual new heat exchanger cleaning procedure schedule 80 as acceptable CPVC material Table 2A R02799 and changes made to Table 5A Revision G ECO C07283 reflects the update of FIG 7 1 on page 38 to show current label and wiring connections along with an update to the Ladder and Wiring diagrams on pages 64 and 65 Revision H ECO C07679 reflects the update of FIG 6 1 page 34 to show the gas pressure regulator ECR 04077 combustible water pipes changed from 1 to a 1 4 addition of the rope gasket notice on page 61 R03940 and changes made to Table 2A on page 19 Revision ECO C07981 reflects the addition of the O temp switch and edits made to LBL200
26. other flammable vapors and liquids CONDENSATE FROM p 2 Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual Inspect boiler interior TO FLOOR DRAIN 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any sediment from inside the boiler and A WARNING que bd doped bs uae a water during all times of boiler operation components Remove any obstructions ii to avoid flue gas emission from the condensate drain line Failure to fill the Clean condensate trap trap could result in severe personal injury or death 1 Inspect the condensate drain line condensate PVC fittings and condensate trap Check all piping for leaks 2 Remove the PVC cap retaining screw from the PVC cap A WARNING Eliminate all system or boiler leaks FIG 11 1 Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating heat exchanger and causing 4 Remove any sediment in the trap heat exchanger failure Leaking water may also cause severe property damage 3 Remove the 2 inch PVC cap with the switch located at the top of the trap FIG 11 1 5 Fill with fresh water until the water begins to po
27. to the latest edition of CGA Standard CAN B149 1 Check all local code requirements for combustion air dimensions based on net free area in square inches Metal louvers or screens reduce the free area of a combustion air SYNC CONDENSING BOILER Installation amp Operation Manual continued Where two openings are provided one must be within 12 30cm of the ceiling and one must be within 12 30cm of the floor of the equipment room Each opening must have net free area as specified in the chart below Table 1B Single openings shall commence within 12 30cm of the ceiling A CAUTION Under no circumstances should the equipment room ever be under negative pressure Particular care should be taken where exhaust fans attic fans clothes dryers compressors air handling units etc may take away air from the unit The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as Freon trichlorethylene perchlorethylene chlorine etc These chemicals when burned form acids which quickly attack the stainless steel heat exchanger headers flue collectors and the vent system The result is improper combustion and a non warrantable premature appliance failure EXHAUST
28. with Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 latest edition Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 when required National Electrical Code For Canada only B149 1 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes NOTICE The SYNC gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21 13 latest edition Before locating the boiler check 1 Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power 2 Locate the appliance so that if water connections should leak water damage will not occur When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance or any of its components 3 Check area around the boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep boiler area clear and free A WARNING of combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage
29. with the PVC CPVC vent materials listed in Table 2C Installing vent and air piping A WARNINGI The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance if PVC CPVC vent is to be used The field provided vent fittings must be cemented to the CPVC pipe section using an All Purpose Cement suitable for PVC and CPVC pipe Use only the vent materials primer and cement specified in Table 2C to make the vent connections Failure to follow this warning could result in fire personal injury or death Use only cleaners primers and solvents that are approved for the materials which are joined together NOTICE All PVC vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a 1 4 inch per foot back to the boiler to allow drainage of condensate Insulation should not be used on PVC or CPVC venting materials The use of insulation will cause increased vent wall temperatures which could result in vent pipe failure NOTICE A WARNING For all installations the first ten 10 ESWARBNINS equivalent feet of vent must be CPVC or stainless steel see FIG 2 6 Failure to follow this warning could result in fire personal inury or death Table 2C PVC CPVC Vent Pipe and Fittings Approved PVC CPVC Vent Pipe and Fittings Standard ANSI ASTM D1785 ANSI ASTM D2665 ANSI ASTM F441 ANSI ASTM D2466 ANSI ASTM D2467 ANSI ASTM F439 PVC Sche
30. 1A thru 3 4B pages 22 and 24 Also maintain the following a Vent must terminate At least 6 feet 1 8 m from adjacent walls No closer than 12 inches 305 mm below roof overhang At least 7 feet 2 1 m above any public walkway Figure 3 3A Clearance to Forced Air Inlets At least 3 feet 9 m above any forced air intake within 10 feet 3 m No closer than 12 inches 305 mm below or horizontally from any door or window or any VENT AIR other gravity air inlet ia b Aur inlet must terminate at least 12 inches 305 m above grade or snow line at least 12 inches 305 mm below the vent termination and the vent pipe must not extend more than 24 inches 610 mm vertically outside the building as shown in FIG s BIRD SCREEN TYPICAL 12 305 MM MIN 12 305 MM MIN IF LESS THAN 10 36 MIN FORCED AIR INLET 3 1B and 3 1C c Do not terminate closer than 4 feet 1 2 m 7 MIN ABOVE ANY horizontally from any electric meter gas meter PUBLIC WALKWAY regulator relief valve or other equipment Never terminate above or below any of these within 4 feet 1 2 m horizontally 6 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment EN 54 EH Sidewall direct venting Figure 3 3B Alternate Clearance to Forced Air Inlets w Field Supplied Fittings Prepare wall penetrations li IF
31. 45 ECR R04243 and C07959 add O temp switch changes made to Table 5A on page 31 ECR R04335 and change Module 1 and 2 callouts to HEX 1 and 2 on the label Revision J ECO C08327 reflects changes made to the temperature callouts under Protection Features on page 50 ECR R04145 Revision ECO C08407 reflects updates made to LBL20045 ECR R04434 along with changing the water outlet from 2 1 2 NPT to 3 NPT ECR R04009 pages 4 6 and 31 and updating the O temp switch description on page 4 Revision L ECO C08689 reflects additional information added to the v humidity warning on page 7 updates made to LBL20046 Rev F ECO r 8689 the addition of the new Polypropylene Vent material section Y and rearranging the venting section High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway ar A a Revision M ECO C09691 reflects the update of AHRI and ASME logos 615 889 8900 Fax 615 547 1000 www Lochinvar com on page 6 SYNC I O Rev M 1 12
32. C Service Manual for more information regarding this screen Main button Pressing this button brings up the Main Screen From this screen navigation to eight 8 other screens is possible Reference the Main Screen section on page 56 of this manual for more information regarding this screen 10 Operating information GYNG CONDENSING BOILER Installation amp Operation Manual Use the Main Menu Screen FIG 10 2 to access the screens necessary to set temperatures operating conditions and monitor boiler operation The SYNC is equipped with a SMART TOUCH control system All menu options are accessed by touching the screen with your finger or a stylus from a PDA Figure 10 2 Main Menu Screen Main Screen gie een ie i pen pA LH sill ia pem i T i gt i Weil aiaa Wen The Main Screen allows navigation to eight 8 additional screens which are used to set temperatures operating conditions and monitor boiler operation These screens are as follows Setup Allows access to seven 7 other screens for the adjustment of the control parameters Cascade Shows the status of multiple boilers connected together in a cascade arrangement Temps Shows the temperatures measured by the individual sensors connected to the boiler Burners Shows the status of the two 2 independent burner systems used in the boiler Building Shows the information from a Building Integration Syste
33. Connection Boards FIG 7 3 If more than two boilers are on the Cascade daisy chain the wiring from the Sequencing terminals on the second boiler to the Sequencing terminals on the third boiler then from the third to the forth and so on The connections between boilers can be made in any order regardless of the addresses of the boilers Try to keep each cable as short as possible Installation amp Operation Manual CONDENSING BOILER SYNC Figure 7 3 Low Voltage Field Wiring Connections F Field wiring continued 1XIN OL POSCAN POCO u3108 SNOIAIYd WOY V O 0 aJgIHS AIO Q I31IHS IQ g u31l08 LX3N OL v OX dy NOILVOINQWINOO Shadow 3IHS g x YOSNIS YNVL a E qmiHS 0 4362 vez RM d asc e HOSN3S YOOALNO zz MQ ES 9 pT YNVLSZ E fi YOSNAS HOSN3S WALSAS o _ Th LAANI AOL 0 a Pi TH JO2IA3Q DNI18VN3 a GND QTIHS 81 e c 941 8 VOL S1 NENNEN QE __ ML JVISOWHSW3H I savna A rr 1 LI Es E E HOLIMS MOTH HOLIMS 01 _ Bi H3ONVHOX3 LX3H 6 RINER O JV3H INCOR Te S Z po ES 208 SNOW D PT MO1J SIOVINOD Y Th CH3ONVHOX3 JWILNNY
34. D DRAIN CONTROL MODULE 2 F T Pe E 4 g lt E E 6 Q Q LOW GAS HIGH GAS PRESSURE SWITCH PRESSURE 1 oo LH i HIGH GAS PRESSURE 2 LOUVER RELAY 2 Aps FLAP VALVE O AUTO RESET LIMIT K TA X ZNVALVE Y ROD FLAME ROD HIGH VOLTAGE SPARK LEAD Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead WIRING DIAGRAM or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components LBL20045 REV K 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using L diagrams to troubleshoot unit _ 5 Notes 66 Notes 67 Revision Notes Revision A ECO C02428 initial release Revision B ECO C03046 reflects the addition of FIG 5 3 on page 27 the addition of a pressure gauge to FIG 5 6 on page 30 edits made to FIG 7 1 on page 35 edits made to the Low Water Cutoff Protection section
35. DRAIN POINT TYPICAL X B y m MAY SUBSTITUTE LOW LOSS FADER ee SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR HOT WATER GENERATOR PRESSURE GAUGE BACK FLOW PREVENTER 7o S Cy MAKE UP WATER PRESSURE REDUCING VALVE EXPANSION TANK WATER GENERATOR CIRCULATOR TYPICAL UNION TYPICAL TEMPERATURE PRESSURE GAUGE PRESSURE RELIEF VALVE HEAT EXCHANGER 1 BOILER PUMP Y STRAINER FLOW CHECK VALVE TYPICAL TO FLOOR RECOMMEND TYPICAL HEAT EXCHANGER 2 DRAIN BOILER PUMP NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes NOTICE System flow should always remain higher than the required flow for the boiler s when the boiler s is in operation to prevent short cycling and high limit issues EH 55 um Installation amp Operation Manual CONDENSING BOILER 5 Hydronic piping continea Figure 5 6 Multiple Boilers Primary Secondary Piping Number of Units Number of Units 3 4 5 6 7 j 8 Manifold Pipe Sizes in Inches mm A system supply sensor factory noe supplied MUST BE installed for proper C boiler operation MAY SUBSTITUTE LOW LOSS HEADER BALL VALVE HOT WATER TYPICAL GENERATOR AIR y SEPARATOR DRAIN POINT E TYPICAL SYSTEM SUPPLY SENSOR
36. Delay cycles At the end of the Post Purge cycle the louver contacts will open The control verifies that the blower stops running and the flap valve closes At the end of the Pump Delay cycle s the pump s will be turned off 53 GYNG Installation amp Operation Manual CONDENSING BOILER 10 Operating information SWYN TOUCH SYNC control module The Status Screen displays boiler status Cascade addresses outlet water temperature inlet water temperature system temperature and tank temperature The boiler can be changed by pressing the ON OFF button The Details Screen and Main Menu Screen can be accessed by pressing the appropriate button Figure 10 1 Status Screen Manual Shutdown D CscdlZ D 1 Cscd Outlet Water 122 Temperature system Water 118 Inlet water Temperature Temperature MI IP ii m ii When the ON OFF switch is turned to the ON position SH BMS The boiler has received a call for heat from the first screen visible on the LCD display will be the Status a 0 10 VDC BMS control Screen This screen displays the current status of the SYNC Service Set Point Met While in Service Mode the boiler The following items can be viewed or interacted with water temperature at either the outlet sensor or the on the Status Screen system sensor has exceeded 185 F e HW Outlet Set Point Met The outlet water temperature has exceeded the HW Generator Set Point
37. G FROM on CONNECTION The air piping must terminate in a down turned elbow as shown in FIG 3 1B This arrangement avoids recirculation of flue products into the combustion air stream The vent piping must terminate in an elbow pointed outward or away from the air inlet as shown in FIG 3 1B Do not exceed the maximum lengths of the outside vent piping shown in FIG s 3 1B and 3 1C Excessive length exposed to the outside could cause freezing of condensate in the vent pipe resulting in potential boiler shutdown Figure 3 1B Alternate Sidewall Termination of Air and Vent w Field Supplied Fittings TO BOILER INTAKE AIR CONNECTION BIRD SCREEN VENT PIPE 12 MIN 15 MAX TERMINATION PLATE BIRD SCREEN GRADE OR SNOW LINE GYNG Installation amp Operation Manual CONDENSING BOILER Sidewall direct venting continues Vent air termination sidewall Figure 3 2A Clearance to Gravity Air Inlets Figure 3 1C Alternate Stainless Steel Sidewall Termination w Field Supplied Fittings NOTICE PVC CPVC or ABS is acceptable air inlet pipe material VENT AIR TO BOILER INTAKE a fe TERMINATION AIR CONNECTION 12 305 MM MIN 15 381 MM MAX FROM BOILER VENT PIPE CONNECTION Figure 3 2B Alternate Clearance to Gravity Air Inlets w Field Supplied Fittings 12 305 MM MIN Table 3B Stainless Steel Sidewall Vent Kits EE een Maintain clearances as shown in FIG s 3
38. Leader boiler The set point will be calculated based on the programmed reset curve parameters See the SYNC Service Manual to program the reset curve If outdoor air reset is not desired do not connect the outdoor air sensor A fixed temperature set point can be programmed into the control 51 10 Operating information If the water temperature at the system supply sensor is less than the set point the turn off offset the off on differential then the control will initiate a call for heat on the Cascade see the SYNC Service Manual for an explanation of the offset and differential The Leader will energize the lead boiler on the Cascade For a new startup this will be the Leader boiler The boiler will fire at its ignition speed and will then modulate its firing rate to maintain the set point If the first boiler reaches 100 of its firing rate the Leader will calculate at what point the second boiler could fire at 10 of its firing rate At this point the Leader will fire the second boiler on the Cascade For a new startup this would be the first Member boiler The boiler will fire at its ignition speed and will then modulate its firing rate to maintain the set point If the set point still cannot be met the Leader will continue firing more Members until either the heat demand is met or all boilers on the Cascade are firing As the heat demand decreases the last boiler on will modulate down to 10 of its firing rate Once the dem
39. S CN1 10 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present 2 See wiring diagram for additional notes CN1 7 A WARNING DISCONNECT POWER iapper piacram BEFORE SERVICING 8120045 REV F GYNG CONDENSING BOILER Installation amp Operation Manual 12 Dia grams continued Figure 12 3 Wiring Diagram J LOW VOLTAGE AWARNING 120 VAC DISCONNECT POWER eee HIGH VOLTAGE BEFORE SERVICING CM 1 PC INTERFACE BOX DEPICTS OPTIONAL ITEMS LOUVER JUNCTION CONTROL CONTACTS BOX MODULE 1 R1 R2 PC INTERFACE _ an XJ CONNECTION BOARD BOILER 2 CM 2 PC Ug Q BOILER 1 INTERFACE sHIELD CASCADE RS485 IN SYSTEM PUMP SHIELD TANK HW PUMP SENSO RELAY Let OUTDOOR SENSOR GND 120V SUPPLY SYSTEM SENSOR we EXTERNAL CONTROL YC F SHIELD MOD BUS RS485 L SHIELD LOUVER RELAY 1 Cort ai P ENABLE TANK o HEX 1 T pee SWITCH N HEX2 OBO W j y FLOW SWITCH LOUVER O PROVING RUNTIME CONTACTS P ALARM CONTACTS L BLOCKE
40. SYNC boiler requires a flow switch to be installed on each inlet 3 Remove the jumper wires from the terminals on the connection board and connect these terminals to the normally open contacts on the flow switches FIG 7 3 f Field wiring System supply sensor 1 By installing the system supply sensor into the supply of the primary loop the temperature of the system supply can be controlled The SMART TOUCH control automatically detects the presence of this sensor and controls the boiler firing rate to maintain the system supply temperature to the set point NOTICE DO NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO THE SYSTEM RETURN 2 Connect these terminals to the system supply sensor FIG 7 3 A system supply sensor factory supplied NOTICE P p P MUST BE installed for proper boiler operation Boiler management system 1 An external control may be connected to control either the firing rate or the set point of the boiler Connect the 0 10 VDC terminals to the 0 10 VDC output of the external control The SMART TOUCH control can be enabled using the Enable output see page 39 or using the voltage applied to the 0 10 VDC input Reference the SYNC Service Manual for more details 2 Make sure the ground terminal is connected to the ground output terminal of the external control and the 0 10 VDC terminal is connected to the 0 10 VDC terminal of the external control Runtime contacts The SMART TOUCH control
41. SYNC I O Rev TM CONDENSING BOILER Installation amp Operation Manual Models 1 0 1 3 1 5 A WARNING This manual must only be used by a qualified heating installer service technician Read all instructions including this manual and the SYNC Service Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Lochinvar Save this manual for future reference High Efficiency Water Heaters Boilers and Pool Heaters HAZARD DEFINITIONS 2 ROOM p S 2j PLEASE READ BEFORE PROCEEDING 3 5 HYDRONIC PIPING THE SYNC HOW IT WORKS 4 5 System Water Piping 28 RATINGS 0 0 cece cccccccccceeceeeeeeeeeeeeeeeeeeseaeeeeeeeeeeeeesseeaaaes 6 Low Water Cutoff Device 28 1 DETERMINE BOILER LOCATION Chilled Water 28 Closet and Alcove Installations 7 26 S 28 Provide Air Openings to Room 9 General Piping Information 28 Flooring FolfidatlOf seii Io Ra
42. UPPLIED EH 5 um GYNG Installation amp Operation Manual 3 Support piping with hangers not by the boiler or its accessories The gas valve and blower will not support 2 the weight of the piping Do not attempt to support the weight of the piping with the boiler or its accessories Failure to comply could result in severe personal injury death or substantial property damage 4 Purge all air from the gas supply piping 5 Before placing the boiler in operation check the boiler and its gas connection for leaks a The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5 kPa b The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5 kPa c The appliance and its gas connection must be leak tested before placing it in operation Do not check for gas leaks with an open d flame use the bubble test Failure to use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 6 Use pipe sealing compound compatible with propane gases Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow IING Failure to apply pipe sealing compound as detailed in this ma
43. X56 5 5 12 TR1 1 7 FLAME ROD HIGH VOLTAGE SPARK LEAD CONTROL CAUTION CONTROL MODULE 1 LADDER DIAGRAM LBL20058 REV E DISCONNECT POWER BEFORE SERVICING 63 GYNG Installation amp Operation Manual 12 Dia grams Figure 12 2 Ladder Diagram_Part 2 BOX DEPICTS OPTIONAL ITEMS LOW VOLTAGE 120 VAC S ON OFF SWITCH CONTROL MODULE 1 JUNCTION BOX ON OFF SWITCH CONTROL MODULE 2 JUNCTION BOX CONNECTION BOARD LOUVER PROVING Bos pls RUN TIME CONTACTS ALARM CONTACTS LWCO J3 5 J3 4 lt gt gt J3 J3 3 TEST SWITCH PROBE EH 5 um HIGH VOLTAGE L1 JUNCTION BOX LOUVER LOUVER SYSTEM PUMP CONTACTS X1 2 RELAY BOILER HEX 1 BOILER PUMP CONTACTS HEX 1 BOILER PUMP RELAY BOILER PUMP y SYSTEM HEX 2 BOILER PUMP CONTACTS Pume JUNCTION BOX RELAY FIELD SUPPLIED SYSTEM PUMP x CONTACTS QS feed d PUMP CONTACTS prse SUPPLIED m LWCO DHW L PUMP LOW GAS HIGH GAS CONTROL PRESSURE PRESSURE MODULE 1 SWITCH SWITCH 1 X6 5 Oa CONTROL X1 2 HIGH GAS MODULE 2 PRESSURE Ee SWITCH 2 n 2 BOILER PUMP X14 iow X1 3 BLOWER X1 1 CONTROL MODULE 1 MC X6 8 CONNECTION BOARD CN1 6 CONTROL S MODULE 2 CN1 5 CN1 6 CN1 3 CN1 11 CN1 15 NOTE
44. aight Feet Capacity of Pipe in Thousands of Btu hr for gas pressures of 14 Inches Water PSIG or less and 180 1 100 974 a pressure drop of 0 5 Inch Water Iron Pipe Size 2 150 1 500 1 210 923 830 4 100 2 820 2 260 1 950 1 720 1 560 Column Based 2 6 460 4 460 3 610 3 100 2 720 2 460 1 540 1 400 1 300 Sn NAT GAS 1025 Btu hr per 3 11 200 7 900 6 400 5 400 4 870 4 41 2 720 2 500 2 340 Cubic Foot of Gas and 0 60 23 500 16 100 13 100 11 100 10 000 9 000 6 870 6 150 5 640 5 130 4 720 Specific Gravity Check inlet gas supply 4 Slowly turn on the gas supply at the field installed manual gas valve NOTICE CSA or UL listed flexible gas connections are 5 Turn the power switch to the ON position acceptable but you must exercise caution to ensure that the line has adequate capacity to Adjust the temperature set point on the control panel of J ON ZEE N allow your boiler to fire at full rate Consult the SMART TOUCH control module to call for heat with local codes for proper installation or 7 Observe the gas supply pressure as the burner fires at service procedures 10096 of rated input Percent of burner input will be A WARNING DO NOT adjust or attempt to measure gas displayed on the Burner Screen valve outlet pressure Attempting to alter g Ensure inlet canes or measure the gas v
45. alve outlet pressure spel an could result in damage to the valve causing specified in this section of the manual potential severe personal injury death or substantial property damage 9 If gas supply pressure is within normal range and no adjustments are needed proceed on to Step 11 The gas piping must be sized for the proper flow and length of pipe to avoid excessive pressure drop Both the gas meter and the gas regulator must be properly sized for the total gas load If the gas pressure is out of range contact the gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide proper gas If you experience a pressure drop greater than 1 inch w c pressure to the control 249 Pa the meter regulator or gas line is undersized or in 11 Turn the power switch to the OFF position need of service Perform the steps below when checking inlet gas supply 12 Shut off the gas supply at the manual gas valve in the gas piping to the appliance 13 Remove manometer from the pressure tap on top of 2 Shut off gas supply at the manual gas valve in the gas the gas valve Remove the 1 8 3 mm field supplied piping to the appliance fitting and reinstall the pipe plug removed in Step 3 3 Remove the 1 8 pipe plug on the flange to the field supplied gas shutoff valve and install a suitable 1 8 fitting field supplied for the manometer t
46. and for that boiler is zero it will shut down As the heat demand decreases further the second to last boiler will modulate down and shut off This will continue until the demand is satisfied and all boilers are shut off Sequence of the cascade To equalize the run time of all boilers on the Cascade the firing sequence will automatically be changed at set intervals For the first 24 hours after initializing the Cascade the sequence will be changed every hour After that the sequence will be changed once every 24 hours The switching on off sequence will be as follows DAY SWITCHING ON SEQUENCE L M1 M2 M3 M4 M5 M6 M7 Day 1 1 hour M2 M3 M4 M5 M6 M7 L M1 M4 M5 M6 M7 L M1 M2 M3 Day 1 2 hours 52 Installation amp Operation Manual HW operation with cascade For HW operation any boiler s in the Cascade can be selected to provide heat for a HW call Select a boiler to be designated as the HW boiler Connect the HW thermostat or sensor to the terminals on the Low Voltage Connection Board marked for the HW Thermostat or sensor When the boiler receives a HW call the Leader control will take that boiler out of the Cascade sequence If another boiler is available the Leader will start it up to take its place The HW boiler will adjust its set point to the programmed HW set point and will adjust its firing rate to maintain this Once the HW call has been satisfied the Leader control will place that boiler back int
47. at the same height to avoid recirculation of flue products and the possibility of severe personal injury death or substantial property damage 2 Place roof penetrations to obtain minimum clearance of 12 inches 305 mm between edge of air intake elbow and adjacent vent pipe of another boiler for U S installations see FIG 4 3 For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of a SYNC boiler is part of a direct vent connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents Figure 4 3 Vertical Terminations with Multiple Boilers 12 305 MM MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET ta 12 305 MM MINIMUM FROM EDGE VENT J OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER BOILER Figure 4 4 Alternate Vertical Terminations with Multiple Boilers 12 305 MM MINIMUM VERTICALLY FROM VENT N OUTLET TO ANY AIR INLET 27 5 Hydronic piping System water piping methods The SYNC is designed to function in a closed loop pressurized system not less than 12 psi 83 kPa A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet It is important to note that the boiler has a pressure drop which must be figured in when sizing the circulators Each boiler installation must have an air elimination device which
48. boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further A WARNING Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in the heat exchanger reducing heat transfer overheating the heat exchanger and causing heat exchanger failure Purge air from water system 1 Purge air from system 2 Open automatic air vent diaphragm type or bladder type expansion tank systems only one turn 3 Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out b Repeat with remaining vents 4 Refill to correct pressure 43 Start up Check for gas leaks ARNING Before starting the boiler and during A WARNING initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Remove the top access panel and smell the interior of the boiler enclosure Do not proceed with startup if there is any indication of a gas leak Use an approved leak detection solution Repair any leaks at once DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or subs
49. by the control module to detect the presence of burner flame 16 Flap valves Prevents recirculation of flue products when only one burner is running 17 Flue gas sensors These sensors monitor the flue gas exit temperature The control modules will modulate and shut down the boiler if the flue gas temperature gets too hot This protects the flue pipe from overheating 18 Flue pipe adapter Allows for the connection of the PVC vent pipe system to the boiler 19 Gas connection pipe Threaded 1 pipe connection delivering gas to the boiler 20 Gas shutoff valves inside unit Manual valves used to isolate the gas valves from the burners 21 Gas shutoff valve outside unit Manual valve used to isolate the gas valve from the gas supply This pipe should be connected to the incoming gas supply for the purpose of 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 SYNC Installation amp Operation Manual CONDENSING BOILER Gas valves The gas valves sense the negative pressure created by the blowers allowing gas to flow only if the gas valves are powered and combustion air is flowing Heat exchanger access covers Allows access to the combustion side of the heat exchanger coils High gas pressure switches Switches provided to detect excessive gas pressure High limits Devices used to monit
50. closes a set of dry contacts whenever the burner is running This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat Alarm contacts The SMART TOUCH control closes another set of contacts whenever the boiler is locked out or the power is turned off This can be used to turn on an alarm or signal a Building Management System that the boiler is down Note that these contacts will close momentarily at the end of each call for heat or at least every 24 hours 40 SYNC Installation amp Operation Manual Wiring of the cascade When wiring the boilers for Cascade operation select one boiler as the Leader boiler The remaining boilers will be designated as Members See page 48 Configuration of the Cascade for a detailed explanation of this procedure Connect the system supply sensor and outdoor air sensor if used to the Leader boiler For the Cascade system to work properly the system supply sensor must be installed system supply sensor factory supplied NOTICE y PPY MUST BE installed for proper boiler operation The location of the system supply sensor should be downstream of the boiler connections in the main system loop FIG s 5 5 and 5 6 The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system supply sensor see FIG 7 3 The Leader control will use the water temperature at the system supply senso
51. creen will display the set point being changed the previous setting of the set point and adjustment buttons 4 adjust the set point press the buttons to change the value being displayed 5 Once the set point has been adjusted to the desired setting press the APPLY button to change the set point and return to the Parameter List Screen 47 Start up 6 Ifno other changes are necessary press the BACK button to return to the Parameter List Screen 7 Once all the necessary adjustments have been made press the BACK button to return to the Setup Screen 8 Press the SAVE button to program all changes made to the set points and return to the Status Screen Leaving the Setup Screen without pressing the SAVE button will erase the changes made to the set points and change them back to their previous settings Note The SAVE button must be pressed to ensure proper programming of the controls Failure to press the SAVE button will require all changes to be reprogrammed Set Hot Water Generator HW operation Verify HW circulator mode The HW Mode is programmed to heat an indirect hot water tank When a tank thermostat or a tank sensor initiates a call for heat the SMART TOUCH control will turn on the HW pumps and turn off the boiler pumps if running If the system pump is running it will remain on When the HW call for heat ends and there is no space heating call for heat the HW pumps will continue to run for
52. d 2 fully ported ball valves When using copper with a 20 temperature rise increase piping to 3 NOTICE It is required that near boiler piping systems utilize Primary Secondary configurations as shown in FIG s 5 5 and 5 6 only The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance Near boiler piping components 1 Boiler piping Boiler system piping MUST be sized per the pipe requirements listed in Table 5A Reducing the pipe size can restrict the flow rate through the boiler causing inadvertent high limit shutdowns and poor system performance 2 Boiler circulating pump Field supplied The boiler circulating pump MUST be sized to meet the specified minimum flow requirements listed in FIG 5 4 3 Hot Water Generator circulating pump Field supplied The pump MUST be sized to meet the specified minimum flow requirements listed in FIG 5 4 Consult the indirect boiler operating guide to determine flow characteristics for the selected product used 4 Boiler isolation valves Field supplied Full port ball valves are required Failure to use full port ball valves could result in a restricted flow rate through the boiler 5 Check valves Field supplied Check valves are required for installation as shown in FIG s 5 5 and 5 6 Failure to install check valves could result in a reverse fl
53. d Adapters STAINLESS STEEL VENT TERMINATION KITS Kit Part Number Model Component Description 6 PVC x e Stainless Steel Adapter KIT30028 SB 1000 1500 6 Stainless Steel Vent Termination 5 6 Stainless Steel Ven Termination Steel Vent Termination 6 Stainless Steel Air Inlet Steel Air Stainless Steel Air Inlet 6 6 PVC x 6 Stainless Steel Adapter x 6 Stainless Steel 6 PVC x 6 Stainless Steel Adapter 6 Stainless Steel x 7 Stainless Steel Adapters 2 KIT30029 SB 1300 CURE 7 Stainless Steel Vent Termination Fi Steel Vent Termination T 7 Stainless Steel Air Inlet o Steel Air Inlet 21 Sidewall direct venting Vent air termination sidewall A WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury death or substantial property damage gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves parapets balconies or decks Failure to comply could result in severe personal injury death or substantial property damage Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual 2 You must consider the surroundings when termina
54. dule 40 80 Vent pipe PVC DWV CPVC Schedule 40 80 PVC Schedule 40 PVC Schedule 80 CPVC Schedule 80 Pipe Cement PVC ANSI ASTM D2564 Primer CPVC ANSI ASTM F493 NOTICE DO NOT USE CELLULAR FOAM CORE PIPE Vent fittings NOTE In Canada CPVC and PVC vent pipe fittings and cement primer must be ULC S636 certified Work from the boiler to vent or air termination Do not exceed the lengths given in this manual for the air or vent piping Cut pipe to the required lengths and deburr the inside and outside of the pipe ends Chamfer outside of each pipe end to ensure even cement distribution when joining Clean all pipe ends and fittings using a clean dry rag Moisture will retard curing and dirt or grease will prevent adhesion Dry fit vent or air piping to ensure proper fit up before assembling any joint The pipe should go a third to two thirds into the fitting to ensure proper sealing after cement is applied Priming and Cementing a Handle fittings and pipes carefully to prevent contamination of surfaces b Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1 2 beyond the socket depth c Apply a second primer coat to the fitting socket d While primer is still wet apply an even coat of approved cement to the pipe equal to the depth of the fitting socket along with an even coat of approved cement to the fitting socket e Apply a second coat of cement to
55. e only your hand to turn the gas control knob smell next to the floor because some gas Never use tools If the handle will not turn by is heavier than air and will settle on the hand don t try to repair it call a qualified service floor technician Force or attempted repair may result WHAT TO DO IF YOU SMELL GAS in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been under water Immediately call a qualified Do not touch any electric switch do service technician to inspect the appliance and not use any phone in your building to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information 8 Turn gas shutoff valve clockwise to ON above on this label Handle will be parallel to pipe 2 Setthe thermostat to lowest setting 9 Install top cover 3 Turn off all electric power to the 10 Turn on all electric power to appliance appliance 11 Set thermostat to desired setting 4 This appliance is equipped with an 12 If the appliance will not operate follow the ignition device which automatically lights instructions To Turn Off Gas To Appliance and the burner Do not try to light the burner call your service technician or gas supplier by hand i Gas Valve Gas Valve 5 Remove front door OPEN CLOSED 6 Turn gas shutoff valves counterclockwise m to OFF Ha
56. em and combustion air quality See also Section 1 of this manual Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes Failure to provide a properly installed vent and air system will cause severe personal injury or death This appliance requires a special venting system Use only approved stainless steel PVC CPVC or polypropylene pipe and fittings listed in Tables 2C 2D and 2F for vent pipe and fittings Failure to comply could result in severe personal injury death or substantial property damage DO NOT mix components from different systems The vent system could fail causing leakage of flue products into the living space Mixing of venting materials will void the warranty and certification of the appliance Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations For closet and alcove installations CPVC polypropylene or stainless steel material MUST BE used in a closet alcove structure Failure to follow this warning could result in fire personal injury or death Improper installation of venting systems may result in injury or death Follow the instructions in Section 1 page 11 of this manual when removing a boiler from an existing vent system Do not connect any other appliance to the vent pi
57. erty damage If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to the boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced Boiler water Thoroughly flush the system without boiler connec
58. es a space heating call for heat it turns on the system pump If the boiler is not heating an indirect HW Hot Water tank it also turns on the boiler pump After the space heating call for heat ends the system pump continues to run for a short period of time If the boiler pump was running it continues to run for a short period of time as well These pump delays are factory set to 30 seconds If different delays are desired the appropriate parameters in the control must be changed See the SYNC Service Manual for a detailed explanation of this procedure Set space heating set point temperature During normal operation space heating set point temperatures can be adjusted from the Set Points Menu Press the following buttons to navigate to the Set Points Menu from the Status Screen E gt 1 To change set point press the SELECT button next to the user set point parameter 2 The first time the user set point parameter is accessed you will be required to enter the user password The user password is 0704 3 Using the keypad enter the password and then press the OK button If the password is not entered correctly the screen will revert to the Parameter List Screen and you will not be able to adjust the set point If a digit has been entered incorrectly press the left arrow key on the keypad to back the digit up If the password has been entered correctly the Parameter Change Screen will appear The Parameter Change S
59. et water temperature is rising too quickly the control will reduce the firing rate to its lowest setting Outdoor air reset If an outdoor air sensor is connected the control module will calculate the set point based on the programmed reset curve The installer can change the slope of the reset curve by several adjustable parameters The user can limit the maximum set point for the system using the space heating set point Boost function If outdoor air reset is active and a space heating demand has been active continuously for a set period of time time adjustable by installer and there has been no HW demands the control will increase the set point by a fixed number of degrees adjustable by installer This process will continue until the space heating demand ends the set point reaches the programmed set point or a maximum of 20 increases has occurred Once the system heat demand is satisfied the set point will revert to the value determined by the reset curve Night setback The controller may be programmed to reduce the space heating set point during a certain time each day A start and stop time can be programmed for each day of the week Flame current support To prevent nuisance shutdowns when the boiler is firing at minimum rates the control will increase the firing rate when the flame signal drops too low 50 SYNC CONDENSING BOILER Installation amp Operation Manual Protection features Outlet tempe
60. eter 7 inch 178 mm hole for 6 inch 152 mm vent pipe 815 inch 203 mm hole for 7 inch 178 mm vent pipe b Insert a galvanized metal thimble in the vent pipe hole when required by local codes 3 Usea sidewall termination plate as a template for correct location of hole centers 4 Follow all local codes for isolation of vent pipe when passing through floors or walls 5 Sealexterior openings thoroughly with exterior caulk Figure 3 AC Alternate Sidewall Termination Assembly PVC CPVC or Stainless Steel GALVANIZED THIMBLE wren REQUIRED BY LOCAL CODES ELBOW p SIDEWALL TERMINATION PLATE VENT PIPING AIR PIPING BIRD SCREEN Multiple vent air terminations 1 When terminating multiple SYNC boilers terminate each vent air connection as described in this manual FIG 3 5A 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 wall penetrations to obtain minimum clearance of 12 inches 305 mm between vent pipe and adjacent air inlet elbow as shown in FIG 3 5A for U S installations For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of a SYNC is part of a direct vent connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents Figure 3 5A Multiple Vent Terminations must al
61. f cleaning the flame sense electrode does not Set the control module display to Parameter Mode improve ground wiring is in good condition and ground and check all settings See Section 1 of the SYNC Service Manual Adjust settings if necessary See Section 1 of the SYNC Service Manual for adjustment procedures Check settings of external limit controls if any and adjust if necessary continuity is satisfactory replace the flame sense electrode See Section 3 Troubleshooting in the SYNC Service Manual for other procedures to deal with low flame signal Review with owner 1 Review the SYNC User s Information Manual with the owner Perform start up and checks x 2 Emphasize the need to perform the maintenance schedule h aa Doer ane GDOSISSIS specie specified in the SYNC User s Information Manual and in this in Section 9 Start up manual as well 2 Verify cold fill pressure is correct and that operating pressure does not go too high 3 Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior 4 Remind the owner to follow the proper shutdown procedure 60 and to schedule an annual start up at the beginning of the next heating season SYNC Installation amp Operation Manual 1 1 Maintenance continued Cleaning boiler heat exchanger For recommended materials including brush appropriate extension s refractory cover and detailed inst
62. g option the following conditions and considerations must be followed The unit MUST be installed with the appropriate room air inlet cover factory installed The equipment room MUST be provided with properly sized openings to assure adequate combustion air Please refer to instructions provided with the room air kit There will be a noticeable increase in the noise level during normal operation from the inlet air opening Using the room air configuration makes the unit vulnerable to combustion air contamination from within the building Please review Section 1 Prevent Combustion Air Contamination to ensure proper installation Vent system and terminations must comply with the standard venting instructions set forth in this manual When utilizing the single pipe method provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Figure 2 5 Room Air Installation FOR DIRECT VENT SYSTEMS REMOVE AIR INLET COVER AND INSTALL RUBBER COUPLING FOR PVC CPVC VENT SYSTEMS OR STAINLESS STEEL ADAPTER FOR STAINLESS STEEL VENT SYSTEMS NOTICE SYNG Installation amp Operation Manual Table 2B Hoom Air Minimum Maximum A
63. gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure The problem is especially noticeable in NEW LP installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines Gas valve replacement The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances As an additional safety feature this gas valve has a flanged connection to the venturi and blower Failure to follow all precautions could result in fire explosion or death DO NOT adjust or attempt to measure gas valve outlet pressure Attempting 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 um f Field wiring ELECTRICAL SHOCK HAZARD For J your safety turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard Failure to do so can cause severe personal injury or death NOTICE Wiring must be N E C Class 1 If original wiring as supplied with boiler must be replaced use only type 105 C wire or equivalent Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edition Label all wires pri
64. han 778 cubic feet for SB1000 models 847 cubic feet for SB1300 models and 914 cubic feet for SB1500 models An alcove is any room which meets the criteria for a closet with the exception that it does not have a door Example Room dimensions 9 feet long 9 feet wide and 9 foot ceiling 9 x 9 x 9 729 cubic feet This would be considered a closet for a SYNC Boiler For closet and alcove installations as shown in FIG s 1 1 and 1 2 CPVC or stainless steel vent material must be used inside the structure The ventilating air openings shown in FIG s 1 1 and 1 2 are required for this arrangement Failure to follow this warning could result in fire personal injury or death Provide clearances Clearances from combustible materials 1 Hot water pipes at least 1 4 6 mm from combustible materials 2 Vent pipe at least 1 25 mm from combustible materials 3 See FIG s 1 1 and 1 2 on page 8 for other clearance minimums Clearances for service access 1 See FIGs 1 1 and 1 2 on page 8 for recommended service clearances If you do not provide the minimum clearances shown it may not be possible to service the boiler without removing it from the space 7 SYNC 1 Determine boiler location Figure 1 1 Closet Installation Minimum Required Clearances 1 4 6 MM MINIMUM CLEARANCE AROUND HOT WATER PIPES 1 25 MM MINIMUM CLEARANCE AROUND VENT PIPES 24 610 MM REAR RECOMMENDED
65. ic air vents Designed to remove trapped air from the heat exchanger coils 6 Blowers The blowers pull in air and gas through the venturis item 35 Air and gas mix inside the blowers and are pushed into the burners where they burn inside the combustion chamber 7 Boiler drain port Location from which the heat exchangers can be drained 8 Boiler inlet temperature sensors These sensors monitor system return water temperature If control module adjusts the boiler firing rate so the inlet temperature selected as the controlling sensor the matches the set point 9 Boiler outlet temperature sensors These sensors monitor boiler outlet water temperature If control module adjusts boiler firing rate so the outlet temperature selected as the controlling sensor the matches the set point 10 Burners not shown Made with metal fiber and stainless steel construction the burners use pre mixed air and gas and provide a wide range of firing rates 11 Condensate drain connection Connects the condensate drain line to a 1 2 PVC union 12 Control modules The control modules respond to internal and external signals and control the blowers gas valves and pumps to meet the heating demand 13 Electronic display Digital controls with touch screen technology and full color display 14 Flame inspection windows The quartz glass windows provide a view of the burner surfaces and flames 15 Flame sensors Used
66. ically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems 28 GYNG Installation amp Operation Manual CONDENSING BOILER General piping information Basic steps are listed below along with illustrations on the following pages FIG s 5 5 and 5 6 which will guide you through the installation of the SYNC reference FIG s 5 1A and 5 1B 1 10 11 Connect the system returns marked Inlet make sure to install with pipe sealant compound Connect the system supply marked Outlet make sure to install with pipe sealant compound Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone Install a backflow preventer on the cold feed make up water line Install a pressure reducing valve on the cold feed make up water line 15 psi 103 kPa nominal Check temperature and pressure gauge shipped separately which should read a minimum pressure of 12 psi 83 kPa Install the circulators as shown on the piping diagrams in this section Make sure the circulators are properly sized for the system and friction loss Install check valves with each boiler circulator Install an expansion tank on the system supply Consult the tank manufacturer s instruction for specific information relating to tank installation Size the expansion tank for the required system volume and capacity Install an
67. inea Stainless steel vent NOTICE Installation of a stainless steel vent system should adhere to the stainless steel vent This product has been approved for use with stainless steel manufacturer s installation instructions using only FasNSeal vent systems supplied with the vent system Use only the materials vent systems and A WARNING bios Figure 2 8 Near Boiler Stainless Steel Venting MR or ecient bu NOTICE PVC CPVC or ABS is acceptable air inlet pipe material manufacturers Failure to comply could result in severe personal injury death or REMOVE PVC CPVC VENT i CONNECTOR WHEN substantial property damage INSTALLING STAINLESS STEEL NOTICE The installer must use a specific vent starter adapter at the flue collar connection supplied by the vent manufacturer to adapt to its vent system See Table 2F for approved vent adapters Discard CPVC starter piece Installations must comply with applicable SONCE national state and local codes Stainless steel vent systems must be listed as a UL 1738 approved system for the United States and a ULC S636 approved system for Canada The SYNC uses model specific combustion air intake and vent piping sizes as detailed in Tables 2A and 2B Increasing or decreasing combustion air NOTICE 5 ME pue or vent piping to sizes not specified in this manual is not authorized Table 2F Approved Stainless Steel Terminations an
68. ing demand has been satisfied the control will delay the next space heating call for a set time period time is adjustable by the installer The time delay will be bypassed if the inlet water temperature drops too far during the delay Boiler system and HW pump control When a space heating call for heat starts and no HW call 1s on the system and boiler pumps are turned on As long as the space heating call for heat is on the system pump will remain on If a HW call for heat 15 on the boiler pumps will wait to turn on until just before the HW pumps turn off After the space heating call for heat ends both pumps will run for an additional period of time When a HW call for heat starts the HW pumps are turned on If a space heating call for heat was on the boiler pumps will turn Off a few seconds after the HW pumps turn on Louver A dry contact is provided to open and close louvers whenever the SYNC boiler requires combustion air from inside the room Connect the Louver End Switch to the Louver Proving Switch input on the Low Voltage Connection Board Temperature control Modulation The SYNC is capable of modulating its firing rate from a minimum of 1096 to a maximum of 10096 The firing rate 1s dictated by the call for heat 1 space heating or hot water generation the heating load and various other temperature limitations 49 10 Operating information Gradient limiting If during operation of the boiler the outl
69. ing for signs of deterioration from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual Start the boiler 1 Read and follow the Operating instructions in FIG 9 2 page 46 If boiler does not start correctly 1 Check for loose connections blown fuse or service switch off 2 Is external limit control if used open Is boiler water temperature above 200 F 93 3 Isthermostat set below room temperature 4 Is gas turned on at meter or boiler 5 Is incoming gas pressure less than 4 inches w c 99 kPa If none of the above corrects the problem refer to the Troubleshooting Section of the SYNC Service Manual Check system and boiler Check water piping 1 Check system piping for leaks If found shut down the boiler and repair immediately See WARNINGS on pages 43 and 44 startup regarding failure to repair leaks 2 Vent any remaining air from the system using manual vents Air in the system will interfere with circulation and cause heat distribution problems and noise SYNC ING BOILER Installation amp Operation Manual Q Check vent piping and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping A WARNING Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas pipi
70. lations must comply with applicable NOTCE national state and local codes For Canadian installation polypropylene vent must be listed as a ULC S636 approved system Installation of a polypropylene vent system NOTICE should adhere to the vent manufacturer s installation instructions supplied with the vent system Centrotherm Eco Systems InnoFlue SW Flex Duravent M amp G Group PolyPro Single Wall PolyPro Flex The installer must use a specific vent starter adapter at the flue collar connection supplied by the vent manufacturer to adapt to its vent system See Table 2E for approved vent adapters Discard CPVC starter piece A WARNING Insulation should not be used on polypropylene venting materials The use of insulation will cause increased vent wall temperatures which could result in vent pipe failure Table 2E Approved Polypropylene Terminations Centrotherm InnoFlue SW Polypropylene Joint Sidewall Retaining Adapter Connector Bracket Figure 2 7 Near Boiler Polypropylene Venting POLYPROPYLENE ADAPTER IMG00024 Duravent Polypro Sidewall Polypropylene Joint Sidewall Adapter Adapter Connector Kit 1000 1500 ISAALO606 NotRequired IATPO0606 ISTAGLO606 FSA 6PVCM 6PPS N A 6PPS HLK These parts are only needed if the sidewall termination assembly is used see FIG 3 4B on page 24 20 SvNG Installation amp Operation Manual CONDENSING BOILER 2 General venting cont
71. llation amp Operation Manual 2 Using the keypad adjust the date and time by working from left to right If a digit has been entered incorrectly press the left arrow key on the keypad to back the digit up If no change is necessary press the BACK button to return to the Parameter List Screen Once the correct date and time have been entered press the OK button on the display to program the date and time into memory and return to the Parameter List Screen The internal clock does not adjust for eee Daylight Savings Time and therefore will require a manual adjustment Configuration of the cascade When installed in a Cascade system the individual controls must be programmed for cascade operation To program the cascade parameters access the Cascade Menu found in the Setup Menu by pressing the following buttons ELM gt gt gt Note The CASCADE button the Main Menu will only display the current status of the cascade 1 Once in the Cascade Setup Menu select the appropriate parameter by pressing the SELECT button 2 The first time the cascade setup parameters are accessed you will be required to enter the service password Enter the service password as described in the SYNC Service Manual 3 Once the password has been entered correctly the Parameter Change Screen will appear The Parameter Change Screen will display the parameter being changed the previous setting of the parameter and adjustment buttons 4
72. llation amp Operation Manual 2 General venting Requirements for installation in Sizing Canada The SYNC boiler uses model specific combustion air 1 Installations must be made with a vent pipe system intake and vent piping sizes as detailed in Table 2A certified to ULC S636 below 2 The first three 3 feet of plastic vent pipe from the When determining equivalent combustion air and vent applianceflueoutlet must be readily accessible for visual length add 5 feet for each 90 elbow and 3 feet for each inspection 45 elbow 3 Thecomponentsofthecertified vent system must not be interchanged with other vent systems or unlisted pipe fittings EXAMPLE 20 feet of PVC pipe 4 90 elbows 2 45 elbows 1 concentric vent kit CVK3003 49 equivalent feet of piping Table 2A Air Intake Vent Piping Sizes Input De Rate per 25 feet of Vent sB 1000 6 t2 10 6 12 125 Air Intake Air Intake Air Intake Diameter Min Length Max Length Diameter Min Length Max Length 5815001 6 1 s eo m 5v 330 SB 1500 1 65 Note When using a 7 vent or air pipe a field supplied increaser is required NOTICE Increasing or decreasing combustion air or vent piping sizes is not authorized 2 General venting ontinuea Materials Air inlet pipe materials The air inlet pipe s must be sealed Choose acceptable combustion air inlet pipe materials from the following list
73. llowable Air Vent Lengths nput Vent De Rate per Diameter 25 feet of 581000 6 1 100 063 SB1300 6 12 100 145 58 1500 6 12 100 165 Air contamination Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds When these chemicals pass through the boiler they can form strong acids The acid can eat through the boiler wall causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building Please read the information given in Table 1A page 10 listing contaminants and areas likely to contain them If contaminating chemicals will be present near the location of the boiler combustion air inlet have your installer pipe the boiler combustion air and vent to another location per this manual A WARNING If the boiler combustion air inlet is located in a laundry room or pool facility for example these areas will always contain hazardous contaminants To prevent the potential of severe personal 4 WARNING injury or death check for areas and products listed in Table 1A page 10 before installing the boiler or air inlet piping If contaminants are found you MUST Remove contaminants permanently OR Relocate air inlet and vent terminations to other areas SYNC Installation amp Operation Manual 2 General venting continea PVC CPVC This product has been approved for use
74. ly but can be reset by the installer Service reminder The control can be programmed for service reminder notification This notification will become active when either a set time frame has expired or a set amount of running hours or cycles has expired all adjustable by the installer The display will alternate the standard text on the display screen with Service Due every 5 seconds The service reminder notification can be reset by the installer Error logging The control will hold in memory the last 10 error codes as well as the last 10 turn off functions The date and time of the occurrence will be recorded as well Only the 10 most current occurrences will be held in memory Boiler temperature regulation Operating temperature target The SMART TOUCH control module senses water temperature and regulates boiler firing and firing rate to achieve a target temperature The target temperature can be set between 70 F 21 C and 190 F 88 C Target temperature is fixed when the outdoor sensor is not installed Target temperature is calculated as described below under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected High limit operations When outlet temperature exceeds 200 F 93 3 C high limit action occurs The boiler shuts down until the outlet water cools down Low water cutoff protection 1 Alow water cutoff device with test and reset functionality is provided i
75. m using Modbus Protocols Graphs Allows the selection of items to be graphed on a chart History Shows the operating and fault history of the two 2 control modules Service Mode Allows the installer to control the fan speed of the individual control modules for the purposes of combustion analysis Service Mode will override all other heat demands however all safeties will remain intact EN jc um Navigation to the Main Screen can be accomplished by pressing the MAIN button at the bottom of the page Reference the SYNC Service Manual for more information regarding the eight 8 accessible screens Time The time is displayed in the upper right hand corner of the display It is displayed in 24 hour format Reference the night setback parameters in the SYNC Servie Manual for information regarding adjusting the date and time Status button Pressing this button displays the Status Screen This screen shows the current status of the SYNC boiler Reference pages 54 55 for more information regarding this screen 1 1 Maintenance SYNG m CONDENSING BOILER Maintenance and annual startup Table 11A Service and Maintenance Schedules Service technician see the following pages for instructions x am lt F v lt lt 4 General e Address reported problems if any Inspect interior clean and vacuum if necessary Clean condensate trap and fill with fresh water
76. meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Boiler operation is based on system temperature Control inputs and outputs Room thermostat zone control This input tells the boiler to provide water for space heating Hot Water Generator HW tank thermostat This input tells the boiler to provide water for heating an indirect HW tank 0 10V input set point or power The SYNC can be controlled by a Building Management System BMS using a 0 10 VDC signal The control can be configured by the installer to use this signal to either control set point or firing rate SYNC Installation amp Operation Manual HW priority The SMART TOUCH control module allows connection of a HW thermostat to the low voltage connection board When the HW thermostat calls for heat the control modules activate the HW pumps shuts down the boiler pumps and immediately sets the target outlet water temperature to 180 F 82 2 C This provides automatic priority heat allocation to the HW Generator for maximum response and recovery The HW pumps continue for 30 seconds after the heating cycle to deliver the most possible heat Controlling sensor The control module is programmed to use the outlet sensor as the control sensor by default If a system supply sensor is connected the control automatically uses it as the control sensor Anti cycling After a space heat
77. n a jacket that contains the combustion process Temperature and pressure gauge Monitors the outlet temperature of the boiler as well as the system water pressure Test switch Test switch for the low water cutoff Hold for 10 seconds to test Top panel Removable panel to gain access to the internal components Venturis The venturis control air and gas flow into the burners Water inlets Two 2 NPT water connections that return water from the system to the heat exchangers Water outlets A 3 NPT water connection that supplies hot water to the system O temp switch located underneath access cover An electrical switch designed to shut down boiler operation in the event the outer back of the heat exchanger directly above the flue connection does not exceed 604 F 318 C This is a one time switch and could warrant a heat exchanger replacement Check the integrity of the rear refractory at the back of the upper coil if the switch opens SvYNG Installation amp Operation Manual CONDENSING BOILER The SYNC How it works continued Models 1 0 1 3 1 5 Front View Rear View 1 0 Model Only 20 Left Side inside unit 24 Right Side inside unit SvNG Installation amp Operation Manual CONDENSING BOILER Ratings Other Specifications Net l Model Number Appliance AHRI Water Ratings Content Note Change N to Water Gallons L for L P gas models p Note 2
78. n on the NOTICE FIG 11 3 If damaged DO NOT reuse the boiler heating surfaces Do not use any solvent heat exchanger door must be replaced Consult 7 Brush the heat exchanger while dry using a nylon bristle factory for replacement heat exchanger door brush Caution DO NOT use a metal brush Re vacuum kit WTR3086 the heat exchanger 8 Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressure water supply 9 Allow the heat exchanger to thoroughly dry 10 Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble 11 Close isolation valves on piping to isolate boiler from system Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make up line to the boiler 12 Perform start up and check out procedures in the Check Flame and Combustion Section 9 Startup on pages 45 and 47 of this manual 13 Replace the access cover and restore boiler to operation 61 GYNG Installation amp Operation Manual 1 1 Maintenance Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING A WARNING 62 The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer
79. n the boiler as standard equipment Flow sensing device 1 The SMART TOUCH control module uses temperature sensing of both supply and return temperatures of the heat exchanger If the flow rate is too low or the outlet temperatures too high the control module modulates down and will shut the boiler off This ensures boiler shutdown in the event of low flow conditions If a mechanical flow switch 1s required to ROUET meet local code requirements the SYNC boiler can be equipped with field supplied switches on each inlet Please reference page 39 of this manual for more information Outdoor reset operation if used Target temperature with outdoor reset This feature improves the system s efficiency as the outdoor temperature warms up See the SYNC Service Manual to change the settings Reset curve The reset curve looks at outdoor air temperature and adjusts the set point Cascade When multiple boilers are installed they can be wired together in a cascade sequence A maximum of eight boilers can be controlled from a single control In this application one boiler would be designated as the Leader control and all others would be designated as Member controls Once the Leader boiler receives a call for heat from the Enable input or 0 10 VDC input the control will determine what the set point will be If outdoor air reset is desired connect the outdoor air sensor to the terminals on the Low Voltage Connection Board on the
80. nal injury death or substantial property damage Do not pipe combustion air near a swimming pool for example Also avoid areas subject to exhaust fumes from laundry facilities These areas will always contain contaminants 1 Determine boiler location Table 1A Corrosive Contaminants and Sources Products to avoid Spray cans containing chloro fluorocarbons Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry cleaning laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops 10 SYNC Installation amp Operation Manual ING BOILER When using an existing vent system to install a new boiler Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe pe
81. ndle will be perpendicular to io CLOSE to OPEN pipe Do not force Pm A 7 Wait five 5 minutes to clear out any gas rr RENT If you then smell gas STOP Follow B A in the safety information above this label If you don t smell gas go to next step TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 4 Turn gas shut off valves counterclockwise to Turn off all electric power to the appliance OFF Handle will be perpendicular to pipe if service is to be performed Do not force Remove front door 5 Install front door LBL20053 REVA 46 Start up continued Check flame and combustion continued 4 Navigate to the Service Mode Screen from the Status Screen by pressing the MAIN button and then the SERVICE MODE button 5 On the Service Screen place Heat Exchanger 1 into operation by selecting Heat Exchanger 1 with the SELECT button and turning the heat exchanger on by pressing the ON OFF button OFF indicates that the heat exchanger is off and ON indicates that the heat exchanger should be firing 6 Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor Note Heat Exchanger 1 is the top heat exchanger please ensure the probe is in the top flue sensor location 7 Once the heat exchanger has modulated up to full fire measure the combustion The values should be in the range listed in Table 9A below CO levels should be less
82. nections Figure 5 1A Near Boiler Piping w Y Strainer DRAIN TYPICAL SYSTEM SUPPLY SENSOR NOTICE A SYSTEM SUPPLY SENSOR MUST BE INSTALLED FOR PROPER BOILER OPERATION SYSTEM PUMP ISOLATION VALVE TYPICAL Y STRAINER RECOMMENDED TYPICAL TEMPERATURE GAUGE HEAT EXCHANGER 1 BOILER PUMP RELIEF VALVE HEAT EXCHANGER 2 BOILER PUMP TO FLOOR DRAIN CHECK VALVE TYPICAL Figure 5 1B Near Boiler Piping w Low Loss Header AIR VENT VALVE LOW LOSS HEADER DRAIN VALVE TYPICAL DRAIN TYPICAL AIR SEPARATOR SYSTEM SENSOR SYSTEM PUMP ISOLATION VALVE TYPICAL SY 70 a Sk A 75 EN Sko UP HEAT EXCHANGER 1 BOILER PUMP EXPANSION TANK Y STRAINER RECOMMENDED TEMPERATURE GAUGE RELIEF VALVE HEAT EXCHANGER 2 BOILER PUMP CHECK VALVE DRAIN TYPICAL 29 TO FLOOR SyNG Installation amp Operation Manual CONDENSING BOILER 5 Hydronic piping Hot Water Generator pump sizing The SYNC has two 2 heat exchangers that require two 2 individual pumps for proper installation in the boiler loop and an additional two 2 pumps for the Hot Water Generator loop Hot Water Pump Head Loss Ft of Head for Heat Exchanger 1 at required flow Ft of Head for the Hot Water Generator at 2 X the flow of Heat Exchanger 1 Example Boiler SB1500 A AT of 30 requires a flow through each heat exchanger of 51 GPM The heat exchanger head loss is 18 ft
83. ng 1 Check around the boiler for gas odor following the procedure on page 34 of this manual connecting gas supply piping If you discover evidence of any gas leak shut down the boiler at once Find the leak source with a bubble test and repair immediately Do not start the boiler again until corrected Failure to comply could result in severe personal injury death or substantial property damage Check flame and combustion 1 Turn the main power off to the boiler by placing the On Off switch in the OFF position 2 Remove the flue temperature sensors from the flue pipe connections Note Combustion measurements will be made at this point 3 Turn the main power on to the boiler by placing the On Off switch in the ON position 45 GYNG Installation amp Operation Manual 9 Start up Figure 9 2 Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot It is Immediately call your gas supplier from equipped with an ignition device which neighbor s phone Follow the gas supplier s automatically lights the burner Do not try instructions to light the burner by hand f you cannot reach your gas supplier call BEFORE OPERATING smell all around the fire department the appliance area for gas Be sure to C Us
84. ns a second line vent may be required and tubing size may need to increase to 1 inch 25 mm The condensate line must remain unobstructed allowing free flow of condensate If condensate is allowed to freeze in the line or if the line is obstructed in any other manner condensate can exit from the boiler tee resulting in potential water damage to property 7 Acondensate removal pump is required if boiler is below drain When installing a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage The switch should be wired to the auxiliary device proving switch terminals on the low voltage connection board 1 2 12 7 mm PVC UNION FACTORY SUPPLIED NEUTRALIZER KIT OR DRAIN PAN EH 9 Start up Check control water chemistry A CAUTION Do not use petroleum based cleaning or sealing compounds in the boiler system Damage to elastomer seals and gaskets in the system could occur resulting in substantial property damage Hardness less than 7 grains 1 Consult local water treatment companies for hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm 1 Do not fill boiler or operate with water containing chlorine in excess of 200 ppm 2 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower 3 Do not
85. nt to all screws or rivets installed in the vent pipe d Ensure that the air inlet pipes are properly supported Installation amp Operation Manual The PVC CPVC or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer s recommended solvents and standard commercial pipe cement for the material used The PVC CPVC ABS Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume A DANGER Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation spillage of flue products and carbon monoxide emissions causing severe personal injury or death 17 2 General venting Optional room air Applications utilizing the SYNC boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room In order to use the room air ventin
86. nual can result in severe personal injury death or substantial property damage Installation amp Operation Manual 6 Gas connections continued Use two wrenches when tightening gas Natural gas supply pressure requirements piping at boiler FIG 6 2 using one 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c 3 5 kPa with no flow lockup or with boiler on Minimum 5 inches w c 1 25 kPa for 1 0 models with gas flowing verify during boiler startup Minimum 4 inches w c 99 kPa for 1 3 1 5 models with gas flowing verify during boiler startup wrench to prevent the boiler gas line connection from turning Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components Figure 6 2 Inlet Pipe with Backup Wrench 2 Install 10096 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c 3 5 kPa at any time Adjust lockup regulator for 14 inches w c 3 5 kPa maximum Propane Gas Am Check boiler rating plate to determine which ESWARNING fuel the boiler is set for SYNC boilers CAN NOT be field converted Failure to comply could result in severe personal injury death or substantial property damage Pipe sizing for propane gas 1 Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Propane Supply Pressure Requirements 1 Adjust propane suppl
87. o the Cascade sequence Night Setback operation with cascade Night Setback operation of the boilers within the Cascade is available Programming of the Night Setback will be done through the Leader boiler Refer to the SYNC Service Manual for information regarding Night Setback SYNC Installation amp Operation Manual ING BOILER 10 Operating information oninueo Sequence of operation Note This unit is equipped with two 2 independent but synchronized combustion systems The Heat Exchanger 1 combustion system will fire first If the demand cannot be met by one 1 combustion system the same sequence of operation will be followed to bring the Heat Exchanger 2 combustion system online Upon a call for heat the control turns on the appropriate pumps system and boiler pumps for a space heating call HW pump relay output for a HW call The control confirms that the low water cutoff and flow switch optional contacts are closed The control starts the blower and closes the louver contacts to begin the Pre Purge cycle The control confirms that the blower comes up to the desired speed the flap valve opens and the air pressure switch gas pressure switch optional louver proving switch optional and blocked drain switch contacts close Once the Pre Purge cycle is complete the control lowers the blower speed initiates sparking of the ignition electrode and opens the gas valve After a short wait the control sto
88. o the boiler room are needed when clearances around the SYNC are at least equal to the SERVICE clearances shown in FIG s 1 1 and 1 2 For spaces that do NOT supply this clearance provide two openings as shown in FIG 1 1 Each opening must provide one square inch free area per 1 000 Btu hr of boiler input 2 Combustion air openings are required when using the Room Air Option on page 18 of this manual The SYNC in same space with other gas or oil fired appliances 1 Follow the National Fuel Gas Code U S or CSA B149 1 Canada to size verify size of the combustion ventilation air openings into the space WARNING The pese must be provided with combustion ventilation air openings correctly sized for all other appliances located in the same space as the SYNC Do not install the boiler in an attic Failure to comply with the above warnings could result in severe personal injury death or substantial property damage 2 Size openings only on the basis of the other appliances in the space No additional air opening free area is needed for the SYNC because it takes its combustion air from outside direct vent installation Flooring and foundation Flooring The SYNC is approved for installation on combustible flooring but must never be installed on carpeting A WARNING Do not install the boiler on carpeting even if foundation is used Fire can result causing severe personal injury death or substantial property damage
89. of head see Table 5A Coupled with a Lochinvar Hot Water Generator with a 8 42 diameter length tube bundle the calculated pressure drop is 1 2 Ft of Head at 102 GPM Hot Water Pump Head Loss 18 Ft Hd 51 GPM 1 2 Ft Hd 102 GPM 19 2 Ft Hd A pump will need to be selected to flow 51 GPM with a head loss of 19 2 Ft Hd Figure 5 2 Boiler Schematic TO SYSTEM FROM SYSTEM En m HEAT EXCHANGER 1 v BOILER PUMP AIR COVER HOT WATER 7 GENERATOR HEAT EXCHANGER 1 HOT WATER TN 51 GPM Hem on 51 om HEAT EXCHANGER 2 HOT WATER PUMP eS DI Figure 5 3 Pump Configuration FROM SYSTEM TO BOILER iT TO BOILER INLETS INLETS 30 5 Hydronic piping oninueo Figure 5 4 Pressure Drop vs Flow SYNG CONDENSING BOILER Installation amp Operation Manual Pressure Drop vs Flow e N e L o 9 9 Lg m 5 m Single Heat Exchanger Only SB1500 SB1300 amp SB1000 Flow Rate GPM Single Tm Exchanger Only Table 5A Sizing Information for Temperature Rise Applications _20 F 25 F 30 F and 35 F TEMPERATURE RISE APPLICATIONS 20F 2 F GPM FTHD GPM FT HD GPM FT HD GPM ES e a Pump sizing and flow requirements ROUGE based on 20 feet 6 m of black iron piping 4 90 elbows an
90. onal injury death or substantial property damage Following installation the valve lever A WARNING must be operated AT LEAST ONCE A YEAR to ensure that waterways are 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 contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing 59 GYNG Installation amp Operation Manual 1 1 Maintenance Inspect ignition and flame Check burner flame sense electrodes Inspect flame through observation window 1 Remove the ignition and flame sense electrodes 2 from the boiler heat exchanger access covers If the flame is unsatisfactory at either high fire or low fire turn off boiler and allow boiler to cool down Remove the burners and clean them thoroughly using a vac
91. or the outlet water temperature If the temperature exceeds its setting they will break the control circuit shutting the boiler down Ignition electrodes Provides direct spark for igniting the burners Line voltage junction box The junction box contains the connection points for the line voltage power and all pumps Line voltage wiring connections knockouts Conduit connection points for the high voltage junction box Low gas pressure switch Switch provided to detect low gas pressure Low voltage connection board The connection board is used to connect external low voltage devices Low voltage wiring connections knockouts Conduit connection points for the low voltage connection board Low water cutoff device LWCO Device used to ensure adequate water is supplied to the boiler and in the event of inadequate water levels will ensure the boiler will shut down Power switch Turns 120 VAC ON OFF to the boiler Pump relay boards The pump relay boards are used to connect the boiler system and Hot Water Generator HW pumps Relief valve Protects the heat exchangers from an over pressure condition The relief valve will be set at 50 PSI Reset switch Reset switch for the low water cutoff Hold for 10 seconds to reset Stainless steel heat exchangers Allows system water to flow through specially designed coils for maximum heat transfer while providing protection against flue gas corrosion The coils are encased i
92. or to disconnection when A CAUTION P servicing controls Wiring errors can cause improper and dangerous operation GYNG CONDENSING BOILER Installation amp Operation Manual Installation must comply with l National Electrical Code and any other national state provincial or local codes or regulations In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Line voltage connections 1 Connect 120 VAC power wiring to the line voltage terminal strip in the junction box as shown in FIG 7 1 Provide and install a fused disconnect or service switch 15 amp recommended as required by the code see FIG 7 1 When connecting hot water generator pumps connect the wiring to the line voltage terminal strip as shown in FIG 7 1 Maximum current is 1 8 amps install a field supplied contactor To activate a system pump wire as shown in FIG 7 1 Dry contacts are sized for 1 5 hp 120V 3 hp 240V or 18 amps To activate a louver connect to the dry contacts provided Contacts are rated for 5 amps 120V Figure 7 1 Line Voltage Field Wiring Connections 120V SUPPLY NEUTRAL W GROUND G gt BK SERVICE SWITCH LINE MODULE HOT WATER GENERATOR MODULE 2 HOT WATER GENERATOR SYSTEM PUMP 1 5HP 120V 3HP 240V MODULE BOILER PUMP 1 5HP 120V 3HP 240V MODULE 2 BOILER PUMP 1 5HP 120V 3HP 240V AlddNs AOCL Wise diNNd MOlVHJN3O M31VM
93. or zero clearance from combustible surfaces and no service access is required from the sides Consult the Venting section of this manual for specific installation instructions for the appropriate type of venting system that you will be using 11 1 Determine boiler location Comb ustion and ventilation air requirements for appliances drawing air from t he equipment room Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes The equipment room MUST be provided with properly sized Openings to assure adequate combustion air and proper ventilation m Figure 1 4 Combustion Air Direct from Outside 1 If air is taken directly from outside the building with no duct provide two permanent openings to the equipment room see FIG 1 4 a 12 Combustion air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5 cm per kW This opening must be located within 12 30 cm of the bottom of the enclosure Ventilation air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5 cm
94. ous situation which if not avoided may result in property damage CAUTION NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage NOTICE SvNG Installation amp Operation Manual CONDENSING BOILER Please read before proceeding Installer Read all instructions including When servicing boiler A WARNING this manual and the SYNC Service NOTICE A WARNING A WARNING Manual before installing Perform steps in the order given User This manual is for use only by a qualified heating installer service technician Refer to the User s Information Manual for your reference 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 When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate Consider piping and installation when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial prop
95. ow condition during pump s off cycle 6 Domestic indirect hot water isolation valves Field supplied Full port ball valves are required Failure to use full port ball valves could result in a restricted flow rate through the boiler 7 Anti scald mixing valve Field supplied An anti scald mixing valve 15 recommended when storing domestic hot water above 115 F 46 8 Unions Field supplied Recommended for unit serviceability 9 Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 10 System temperature sensor Lochinvar supplies a system temperature sensor The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction The sensor should be located far enough downstream to sense system diluted water temperature A system supply sensor factory supplied MUST BE installed for proper boiler operation 11 Y Strainer Field supplied A Y strainer or equivalent multipurpose strainer is recommended at the inlet of the heat exchanger to remove system particles from older hydronic systems and protect newer systems 31 SYNG Installation amp Operation Manual CONDENSING BOILER 5 Hydronic piping Figure 5 5 Single Boiler Primary Secondary Piping A system supply sensor factory supplied MUST BE installed for proper boiler operation BALL VALVE TYPICAL AIR SEPERATOR
96. pe or multiple boilers to a common vent pipe Failure to comply could result in severe personal injury death or substantial property damage The SYNC boiler vent and air piping can be installed through the roof or through a sidewall Follow the procedures in this manual for the method chosen Refer to the information in this manual to determine acceptable vent and air piping length You may use any of the vent air piping methods covered in this manual Do not attempt to install the SYNC boiler using any other means You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions on page 18 ofthis manual The resultant installation is direct vent sealed combustion Air intake vent connections l Combustion Air Intake Connector FIG 2 4 Used to provide combustion air directly to the unit from outdoors A fitting is provided on the unit for final connection Combustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 Vent Connector FIG s 2 5 thru 2 8 Used to provide a passageway for conveying combustion gases to the outside A transition fitting is provided on the unit for final connection Vent piping must be supported per the National Building Code Section 305 Table 305 4 or as local codes dictate Figure 2 4 Near Boiler Air Piping AIR 15 Insta
97. per kW This opening must be located within 12 30 cm of the top of the enclosure SYNC Figure 1 5 Combustion Air Through Ducts 2 If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu hr 11 cm per kW of input see FIG 1 5 5 IF NECE FORTI CONSTRUCTION Figure 1 6 Combustion Air from Interior Space 3 If air is taken from another interior space each of the two openings specified above should have a net free area of one square inch for each 1000 Btu hr 22 cm per kW of input but not less than 100 square inches 645 cm see FIG 1 6 Installation amp Operation Manual ARY HT 1 Determine boiler location T Figure 1 7_Combustion Air from Outside Single Opening 4 If a single combustion air opening is provided to bring combustion air in directly from the outdoors the opening must be sized based on a minimum free area of one square inch per 3000 Btu hr 7 cm per kW This opening must be located within 12 30 cm of the top of the enclosure see FIG 1 7 Combustion air requirements are based on the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada refer
98. ps sparking and checks for the presence of flame current through the spark and flame sense electrodes If the control does not detect flame current the control will lockout indefinitely until the RESET button on the touch screen LCD is pressed If the control detects flame current the control will hold the blower speed constant for a few seconds to allow the flame to stabilize then begin modulating the firing rate in order to maintain the controlling sensor to the desired set point temperature If the current call for heat is for space heating and a HW call for heat becomes active the control will turn on the HW pump relay output then turn off the boiler pumps It will then modulate the blower speed in order to maintain the outlet temperature to the desired HW outlet set point temperature If the first heat exchanger in the boiler is unable to maintain the desired set point temperature the second heat exchanger in the boiler will be started using much of the same sequences as described above Once both heat exchangers are firing the controls will work in synchronization to maintain the desired set point temperature If the heat load should decrease sufficiently the second heat exchanger will be shut down much like the sequences described below Once both the space heating and HW calls for heat are satisified the control will turn off the gas valve and begin the Post Purge cycle Any pumps that are running will begin their respective Pump
99. r to control the operation of the Cascade If outdoor air reset is desired the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor on the Leader boiler FIG 7 3 If the outdoor air sensor is connected the Leader control will calculate the water temperature set point based on the programmed reset curve parameters If the outdoor air sensor is not connected the Leader control will maintain the fixed water temperature set point that is programmed into the control If a Thermostat or Zone Control enable output is available it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked Enable FIG 7 3 If the boilers are to run continuously connect a jumper wire between the R and W terminals at the Enable input This will initiate a call for heat on the Cascade If the SMART TOUCH control is being controlled by a Boiler Management System BMS a call for heat may be initiated by the voltage applied to the 0 10 VDC input Communication between the Leader boiler and the Member boilers is accomplished by using shielded 2 wire twisted pair communication cable Connect one of the twisted pair wires to terminal A on each of the Low Voltage Connection boards and the other wire of the twisted pair to terminal B on each of the Low Voltage Connection Boards Connect the shield wires to one of the shield ground terminals on the Low Voltage
100. rature flue temperature and temperature rise limiting The outlet temperature is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 185 F 85 C the unit will reduce the fan speed If the outlet water temperature exceeds 195 F 90 C the control will shut the unit down until it cools off The control module monitors the flue temperature by a sensor located in the flue exhaust If the flue temperature exceeds 215 F 102 C the control will reduce the maximum fan speed If the flue temperature exceeds 240 F 115 C the control will shut the unit down The unit will restart automatically once the flue temperature drops 25 F 14 C and the minimum off time has expired The control monitors the temperature difference between the inlet and the outlet sensor If this difference exceeds 55 F 31 C the control will reduce the fan speed If the temperature difference exceeds 60 F 33 C the control will shut the unit down The unit will restart automatically once the temperature difference has dropped below 55 F 31 C and the minimum off time has expired Freeze protection DO NOT install the boiler in a room likely to freeze The following integral feature of the SMART TOUCH control module provides some protection for the boiler only not for the system The SMART TOUCH control module provides freeze up protection as follows when the boiler water temperature drops below 45 F 7 C e Below 45 F 7 C
101. re generis roles 9 Girc lator SIZING 29 Vent and Air soc studeo anns einde 9 Near Boiler Piping 29 Prevent Combustion Air Contamination 9 Near Boiler Piping Components 31 33 Using an Existing Vent System to Install a New Boiler 10 6 GAS CONNECTIONS Corrosive Contaminants and Sources 10 Connecting Gas Supply Piping 34 Removing a Boiler from Existing Common Vent 11 C 35 Remove Boiler from Wood 11 Pipe Sizing for Natural 35 Combustion and Ventilation Air Requirements 12 13 Natural Gas Supply Pressure Requirements 35 2 GENERAL VENTING miei iC PT 35 Direct Venting Options Sdwl Horz Vent Opt Rm Air 14 Pipe Sizing for Propane 35 Direct Venting Options Vert Vent Opt Rm Air 15 Propane Supply Pressure Requirements 35 Direct Venting Options Vert Vent Horz Air 16 Check Inlet Gas Supply 36 37 Install Vent and Combustion Air Piping 17 Gas Pressure
102. rsonal injury or death Check the following venting components before installing Material For materials listed for use with this appliance see Section 2 General Venting For polypropylene or stainless steel venting an adapter of the same manufacturer must be used at the flue collar connection Size To ensure proper pipe size is in place see Table 2A Check to see that this size is used throughout the vent system Manufacturer For a stainless steel or polypropylene application you must use only the listed manufacturers and their type product listed in Tables 2D and 2F for CAT IV positive pressure venting with flue producing condensate Supports Non combustible supports must be in place allowing a minimum 1 4 rise per foot The supports should adequately prevent sagging and vertical slippage by distributing the vent system weight For additional information consult the vent manufacturer s instructions for installation Terminations Carefully review Sections 2 through 4 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section For stainless steel vent only use terminations listed in Table 2F for the manufacturer of the installed vent Seal With prior requirements met the system should be tested to the procedure listed in parts c through f of the Removal of
103. rt the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate Seal all wall cavities 24 SYNC Installation amp Operation Manual 8 PVC CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual 9 Stainless steel terminations are designed to penetrate walls with a thickness up to 9 25 inches of standard construction Figure 3 4A PVC CPVC Sidewall Termination Assembly AIR PIPING VENT PIPING SS VENT PLATE WALL PLATE VENT CAP GALVANIZED THIMBLE Table 3C Sidewall Vent Centerline Dimensions A e 60 734 Figure 3 4B Polypropylene Sidewall Termination Assembly SIDEWALL ADAPTER AIR WALL PLATE SIDEWALL RETAINING SIDEWALL ADAPTER VENT GALVANIZED IMG00085 THIMBLE SYNC Installation amp Operation Manual CONDENSING BOILER Sidewall direct venting continues Prepare wall penetrations Alternate Field Supplied Options 1 Air pipe penetration see FIG 3 4B a Cuta hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter 2 Vent pipe penetration see FIG 3 4B a Cuta hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diam
104. rtion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA and or CAN CSA B149 1 Natural Gas and Propane Installation Code Remove boiler from wood pallet 1 After removing the outer shipping carton from the boiler remove the parts package packaged parts inside the jacket of the boiler 2 To remove the boiler from the pallet a Remove the front door of the boiler b Remove the two lag bolts from the wood pallet inside the boiler FIG 1 3 c Detach the boiler from the lag bolts in the rear of the unit see FIG 1 3 Do not drop the boiler or bump the jacket NOTICE oi the floor or pallet Damage to the boiler can result Figure 1 3 Boiler Mounted on Shipping Pallet LAG BOLTS QTY 3 FRONT LAG BOLTS QTY 3 Maintain minimum specified clearances for adequate operation installations must allow sufficient space for servicing the vent connections water pipe connections piping and other auxiliary equipment as well as the appliance The clearance labels on each appliance note the same service and combustible clearance requirements as shown in this manual Multiple appliances may be installed in a modular boiler installation Multiple appliances may be installed side by side with no clearance between adjacent appliances because this appliance is approved f
105. ructions see Model Part Component Table 11B Heat Exchanger Cleaning Kits Number Number Description Table 11B Heat Exchanger Cleaning Kits 1 Shut down boiler Follow the To Turn Gas to Appliance instructions PO Weer SB 1 0 1 5 KIT30064 MSC20085 1 4 x 12 Drill Extension Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid MSC20086 11 4 x 24 Drill Extension in system do not drain Do NOT use a metal brush Only use the kit provided brush or an equivalent replacement nylon brush 2 Allow time for the boiler to cool to room temperature if it CAUTION has been firing 3 Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside 4 Remove the heat exchanger access cover burner and gas air arm assembly A WARNING The boiler contains ceramic fiber materials Use care when handling these materials per instructions on page 62 of this manual Failure to comply could result in severe personal injury 5 Remove the condensate hose from the heat exchanger end Connect field supplied 3 4 diameter hose to a drain pan CAUTION IF GASKETISDAMAGED tL 0 Using field supplied means cover the refractory in the back ti a of the combustion chamber of the heat exchanger NOTICE Rope gasket is intended for sealing combustion 6 Use a vacuum cleaner to remove any accumulatio
106. sion tank Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 5 Hydronic Piping for suggested best location of expansion tanks and air eliminators Check boiler relief valve Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 5 Hydronic Piping before proceeding further SYNC Installation amp Operation Manual Safety relief valves should be re inspected ay inn AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe pers
107. so comply with Figure 3 1A 12 MIN BETWEEN EDGE OF AIR INLET AND ADJACENT VENT OUTLET VENT AIR VENT AIR TERMINATION Figure 3 5B Alternate Multiple Vent Terminations w Field Supplied Fittings must also comply with Figure 3 1B 12 305 MM MIN 15 381 MM MAX 12 305 MM MIN BETWEEN EDGE OF AIR PIPE AND ADJACENT VENT PIPE 4 Vertical direct venting Vent air termination vertical A WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury death or substantial property damage Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual 2 Prepare the vent termination and the air termination elbow FIG 4 1 by inserting bird screens Bird screens should be obtained locally 3 The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet 4 The air piping must terminate in a down turned 180 return pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 5 The vent piping must terminate in an up turned coupling as shown in FIG 4 1 The top of the coupling must be a
108. t least 1 foot above the air intake When the vent termination uses a rain cap as illustrated in FIG 4 1 maintain at least 36 914 mm above the air inlet The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet 6 m apart and with the vent termination at least 1 foot for PVC and 3 feet for stainless steel above the air intake 6 Maintain the required dimensions of the finished termination piping as shown in FIG 4 1 7 Do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe A WARNING Rooftop vent and air inlet terminations must terminate in the same pressure zone unless vertical vent sidewall air is set up as shown in the General Venting Vertical Vent Sidewall Air Section 26 SyNG Installation amp Operation Manual CONDENSING BOILER Figure 4 1 PVC CPVC Polypropylene Vertical Termination of Air and Vent ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 610 MM OF VENT PIPE BIRD SCREEN TYPICAL COUPLING FIELD SUPPLIED 6 152 MM MINIMUM ABOVE ROOF SNOW LINE VENT OUTLET T ABOVE AIR INLET b ARI ur Figure 4 2 Stainless Steel Vertical Termination of Air and Vent ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 610 MM OF VENT PIPE BIRD SCREEN TYPICAL
109. tantial property damage Figure 9 1 Condensate Trap PVC TEE ASSEMBLY FACTORY SUPPLIED 44 2 PVC CAP WITH BLOCKED DRAIN SWITCH RETAINING SCREW CONDENSATE FROM S HEAT EXCHANGER TO FLOOR DRAIN GYNG Installation amp Operation Manual CONDENSING BOILER Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas Check thermostat circuit s 1 Disconnect the two external wires connected to the enable terminals on the connection board 2 Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 Ifa voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves 5 Once the external boiler enable wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the connection board Allow the boiler to cycle Inspect fill condensate system Inspect check condensate lines and fittings 1 Inspect the condensate drain line condensate PVC fittings and condensate trap
110. ted to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment e Do not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage e Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent the need for makeup water Freeze protection fluids NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems The SYNC How it works 1 Access cover front Provides access to the gas train and the heat exchanger 2 Air intake adapter Allows for the connection of the PVC air intake pipe to the boiler 3 Air pressure switches The air pressure switches detect blocked flue vent conditions 4 Air shrouds 1 0 Model only The air shrouds control air and gas flow into the burners 5 Automat
111. terior space must be 50 cubic feet per 1 000 Btu hr input Buildings MUST NOT be of Tight Construction For buildings of Tight Construction provide air openings into the building from outside No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per 1 000 Btu hr of all installed gas fired appliances Buildings MUST NOT be of Tight Construction Tight Construction is defined as a building with less than 0 40 ACH air changes per hour 13 GYNG Installation amp Operation Manual 2 General venting Direct venting options Sidewall Vent N spese a Figure 2 1 Two Pipe Sidewall Termination See page 22 for more details Direct venting options Vertical Vent EM EE SD f V SDN NN S s gt ge TN NS A VLL Figure 2 2 Two Pipe Vertical Termination Figure 2 3 Vertical Vent Sidewall Air See See page 26 for more details page 18 for more details 14 SYNC Installation amp Operation Manual 2 General venting continued Install vent and combustion air piping A WARNING A WARNING A CAUTION A WARNING The SYNC boiler must be vented and supplied with combustion and ventilation air as described in this section Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system air syst
112. than 200 ppm for a properly installed unit If the combustion is not within range reference the Troubleshooting Section in the SYNC Service Manual for possible causes and corrective actions Table 9A Flue Products Chart Cedo ree e 8 0 10 3 0 6 5 9 0 11 4 1 6 9 8 Once the Heat Exchanger 1 analysis is complete test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that Heat Exchanger 1 shuts down and registers an alarm Open the manual shutoff valve reset the control and return to Service Mode 9 Repeat the same procedure for Heat Exchanger 2 by selecting Heat Exchanger 2 while on the Service Mode Screen Be certain to insert the probe from the combustion analyzer into the Heat Exchanger 2 flue temperature sensor location 10 Turn the main power off to the boiler and replace the flue temperature sensor into the flue pipe connection 11 Place the boiler back into normal operation A WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage GYNG Installation amp Operation Manual CONDENSING BOILER Set space heating operation Verify space heat circulator mode The Space Heating Mode controls the system pump if connected and both boiler pumps When the SMART TOUCH control receiv
113. the pipe f While the cement is still wet insert the pipe into the fitting if possible twist the pipe a 1 4 turn as you insert it NOTE If voids are present sufficient cement was not applied and joint could be defective Wipeexcesscement from the joint removing ring or beads as it will needlessly soften the pipe Figure 2 6 Near Boiler PVC CPVC Venting CPVC ELBOW 19 2 General venting Polypropylene This product has been approved for use with polypropylene vent with the manufacturers listed in Table 2D All terminations must comply with listed options in this manual and be a single wall vent offering For use of flex pipe it is recommended to have the vent material in 32 F or higher ambient space before bending at installation No bends should be made to greater than 45 and ONLY installed in vertical or near vertical installations For support and special connections required see the manufacturer s instructions All vent is to conform to standard diameter and equivalent length requirements established Table 2D Polypropylene Vent Pipe and Fittings Approved Polypropylene Vent Manufacturers SYNG CONDENSING BOILER Installation amp Operation Manual Use only the adapters and vent system listed Tables 2 and 2F DO NOT mix vent systems of different types or manufacturers Failure to comply could result in severe personal injury death or substantial property damage Instal
114. ting the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas A WARNING Sidewall vent and air inlet terminations must terminate in the same pressure zone f Do not terminate above any door or window Condensate can freeze causing ice formations Locate or guard vent to prevent condensate damage to exterior finishes 22 SYNC CONDENSING BOILER Installation amp Operation Manual Figure 3 1A PVC CPVC Centrotherm Sidewall Termination of Air and Vent Note Available in 6 diameter only VENT PIPE CONNECTION VENT AIR TERMINATION GRADE OR SNOW LINE Table 3A CPVC PVC Sidewall Vent Kits If using the alternate sidewall termination 3 A WARNIN
115. ttings cccccccesseeesessseeeeeeeeeeees 25 Status DOTEE MERIT E E o m 54 55 Multiple Vent Air 25 Main 550 iis 56 4 VERTICAL DIRECT VENTING 11 MAINTENANCE Vent Air Termination Vertical 26 27 Maintenance amp Annual Startup 57 62 Determine 26 12 DIAGRAMS Prepare Roof Penetrations 26 Ladder Diagrams 63 64 Termination and Fittings asesor irc pta brc espcciruus 26 27 Wining Diagrami sssi 65 Multiple Vent Air 27 Revision Back Cover Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER ene indicates an imminently hazardous situation which if not avoided will result in death or serious A WARNING um indicates a potentially hazardous situation which if not avoided could result in death or serious A CAUTION indicates potentially hazardous situation which if not avoided may result in minor moderate CAUTION used without the safety alert symbol indicates a potentially hazard
116. ubing Place the tubing of the manometer over the tap once the 1 8 fitting is installed as shown in FIG 6 3 36 GYNG 6 Gas connections continued 14 15 16 17 1 Do not check for gas leaks with an open flame use the bubble test Failure to use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage Turn on the gas supply at the manual gas valve Turn the power switch to the position Adjust the temperature set point on the control panel of the SMART TOUCH control module to the desired water temperature so the appliance will call for heat Check burner performance by cycling the system while you observe burner response The burner should ignite promptly Flame pattern should be stable Turn system off and allow burner to cool then cycle burner again to ensure proper ignition and flame characteristics Figure 6 3 Inlet Gas Supply Check CONDENSING BOILER Installation amp Operation Manual Gas Pressure The gas pressure must remain between 4 inches w c 99 kPa minimum 5 inches w c for 1 0 models and 14 inches w c 3 5 kPa maximum for Natural gas and between 8 inches w c 1 9 kPa minimum and 14 inches w c 3 5 kPa maximum for LP gas during standby static mode and while in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet 3 m from the SYNC boiler It is very important that the
117. unning for a fixed time to remove any residual heat 54 Installation amp Operation Manual CONDENSING BOILER 10 Operating information Shutdown Boiler configuration Outlet Water Temperature System Water Temperature lii DENIS Boiler Configuration This line shows the current configuration of the two control modules inside the unit Outlet Water Temperature This is a calculated temperature based on the readings of the outlet temperatures of the two 2 heat exchangers System Water Temperature This is the water temperature as measured by the system supply sensor located in the downstream piping Inlet Water Temperature This is a calculated temperature based on the inlet temperature readings from the two 2 heat exchangers 1 0 1 2 0 1 Cscd Biia Inlet water a Temperature Hot Water Tank Temperature This is the temperature as measured by the tank sensor in the hot water storage tank Time The time is displayed in the upper right hand corner of the display It is displayed in 24 hour format Reference the SYNC Service Manual for Night Setback parameters and more information regarding adjusting the date and time Details button Pressing this button brings up the Details Screen This screen shows the status of the various safeties inputs and outputs to each control module Reference the Details Screen section in the SYN
118. ur out of 1 Inspect all water and gas piping and verify to be leak free the drain 6 Replace the cap Press the cap onto the trap until the cap 2 Look for signs of leaking lines and correct any problems makes contact with the drain found 3 Check gas line using the procedure found in Section 6 7 Replace the retaining screw Gas Connections 58 1 1 Maintenance continued Flue vent system and air piping l Visually inspect the entire flue gas venting system and air piping for blockage deterioration or leakage Repair any joints that show signs of leakage Verify that air inlet pipe is connected and properly sealed Verify that boiler vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system 1 Verify all system components are correctly installed and operational Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 psi 82 7 kPa Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Excessive pressure rise indicates expansion tank sizing or performance problem Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents Check expan
119. use the boiler to directly heat swimming pool or spa water Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer s instructions Freeze protection when used l Determine freeze protection fluid quantity using system water content following fluid manufacturer s instructions Boiler water content is listed on page 6 Remember to include expansion tank water content 2 Local codes may require a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level Fill and test water system 1 Fill system only after ensuring the water meets the requirements of this manual 2 Close manual and automatic air vents and boiler drain valve 3 Fillto correct system pressure Correct pressure will vary with each application a The minimum cold water fil pressure for a commercial system is 12 psi 82 7 kPa b Pressure will rise when boiler is turned on and system water temperature increases SYNC CONDENSING BOILER Installation amp Operation Manual 4 At initial fill and during
120. uum cleaner or compressed air Do not use compressed air to clean burners if performed inside a building 2 Remove any deposits accumulated on the ignition flame sense electrode using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones 3 Remove the burners reference FIG 11 2 When replacing the burners ensure gaskets are in good condition and positioned correctly FIG 11 2 3 Replace ignition flame sense electrodes making 4 sure the gaskets are in good condition and correctly positioned Figure 11 2 Burner Assembly Check ignition ground wiring DOOR FIBER BURNER DOOR BURNER DOOR HEX NUT 6 1 Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip BURNER 2 Verify all wiring is in good condition and securely attached AIR GAS GASKET FLAPPER VALVE SCREW 5X FLAPPER VALVE 3 Check ground continuity of wiring using continuity IGNITER GASKET meter FLAME SENSE GASKET IGNITER SCREW 2X 2 FLAME SENSE 4 Replace ground wires if ground continuity is not SCREW 2X satisfactory Check all boiler wiring Check flame signal 1 Inspect all boiler wiring making sure wires are in 1 At high fire the flame signal shown the display should be at good condition and securely attached least 10 microamps Check control setti ngs 2 A lower flame signal may indicate a fouled or damaged flame sense electrode I
121. will remove air from the system Install the boiler so the gas ignition system components are protected from water dripping spraying etc during appliance operation or basic service of circulator replacement valves and others Observe a minimum of 1 4 inch 6 mm clearance around all un insulated hot water pipes when openings around the pipes are not protected by non combustible materials Low water cutoff device An electronic low water cutoff is provided as standard equipment on all models The low water cutoff should be inspected every 6 months Chilled water system If the boiler supplies hot water to heating coils in air handler units flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle A chilled water medium must be piped in parallel with the heater Freeze protection Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose This includes inhibitors which prevent the glycol from attacking the metallic system components Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level The system should be tested at least once a year and as recommended by the producer of the glycol solution Allowance should be made for the expansion of the glycol solution in the system piping Use only inhibited propylene glycol solutions which are specif
122. y M Breathing Fresh air 12 Diagrams Figure 12 1 Ladder Diagram_Part 1 MODULE 1 LOUVER RELAY 1 de X5 7 X5 4 O O O FLAP AIR PRESSURE VALVE SWITCH X5 14 o lt HI LIMIT OUTLET SENSOR FLUE SENSOR O BLOCKED DRAIN AUTO RESET X5 10 5 HIGH LIMIT GAS VALVE X2 2 GAS VALVE 2 1 RELAY BLOWER 1 X5 5 2 X5 13 4 X5 6 5 X5 12 TR1 CAUTION CONNECTION BOARD SHIELD ZA CN3 15 MEME CASCADE RS485 J SHIELD TANK SENSOR OUTDOOR SENSOR SYSTEM SENSOR EXTERNAL CONTROL YC SHIELD MOD BUS RS485 SHIELD NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present 2 See wiring diagram for additional notes CONTROL HIGH VOLTAGE SPARK LEAD GYNG CONDENSING BOILER Installation amp Operation Manual BOXDEPICTS OPTIONAL ITEMS LOW VOLTAGE 120 VAC HIGH VOLTAGE CONTROL MODULE 2 LOUVER RELAY 2 FLAP AIR PRESSURE VALVE SWITCH X5 14 O HI LIMIT X6 8 INLET SENSOR OUTLET SENSOR FLUE SENSOR AUTO RESET _ HIGH LIMIT X510 GAS VALVE x22 GAS VALVE 2 1 RELAY BLOWER 4 X5 5 2 X518 4
123. y regulator provided by the gas USE BACK UP WRENCH TO supplier for 14 inches w c 3 5 kPa maximum pressure PREVENT PIPE FROM ROTATING 2 Pressure required at gas valve inlet pressure port NOTICE Maximum inlet gas pressure must not Maximum 14 inches w c 3 5 kPa with no flow lockup exceed the value specified Minimum or with boiler on value listed is for the purposes of input Minimum 8 inches w c 1 9 kPa with gas flowing verify adjustment during boiler startup Natural gas A WARNING Ensure that the high gas pressure regulator is at least 10 feet 3 m upstream of the Check boiler rating plate to determine appli A ppliance A WARNING which fuel the boiler is set for SYNC boilers CANNOT be field converted Failure to comply could result in severe personal injury death or substantial property damage Pipe sizing for natural gas 1 Refer to Table 6A for pipe length and diameter Based on rated boiler input divide by 1 000 to obtain cubic feet per hour a Table 6A is only for natural gas with specific gravity 0 60 inches with a pressure drop through the gas piping of 0 5 inches w c b For additional gas pipe sizing information refer to ANSI Z223 1 or B149 1 for Canadian installations 35 SvNG Installation amp Operation Manual CONDENSING BOILER 6 Gas connections Table 6A Natural Gas Pipe Size Chart TABLE 6A GAS PIPING SIZE CHART Nominal Maximum 64 Length of Pipe in Str

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