Venting - Lochinvar
Contents
1. combustion 13 Tho SYNC foatures an 1 1 2 gas connection The gas pipe size from the meter too boller may be larger than the appliance connection and must be properly calculated using the chart below In some cases gas pressure regulator will be required to reduce the supply pressure fo he boler The table below sts the Minimum and Maximum Inlet Gas Pressure INLET GAS PRESSURE Vedal Tung NATURAL GAS TEGE Number Code Varme mawe macwe Maus ma 50 140 80 van 42 140 20 5881500 ma van 40 140 so LP GAS MODELS IW you require modal for connection to LP gas make sure that is noted on your design specification Example the model number changes trom SEN1500 to SBL1500 from natural to LP gas The SYNG must be factory timmed for the chosen gas type and may not ba ied converted trom Natural to LP gas or rom L P to Natural gas GAS PRESSURE REGULATORS Lochinvar recommends the use of Lock Up Type gas pressure regulators on the system gas supply A Lack Up Type gas pressure regulator features seat thal seals the regulator orlice when the appliance I off and there is demand for gas The seat wil seal against the orifice Shutting off the of gas to the appliance A standard regulator without a Lock Lip mechanism will alow the system pressure to reach the bailer when ttis off The system pressure can creep up2. When venting with PVC the first ten feet of pipa must be CPVC far heat protection See Page 12 of the instalation manual for details VENT VENT VENT MODEL DIAMETER MIN LENGTH MAX LENGTH SEN1000 nr SeN1300 ur 1008 SENISOD 1008 SIDEWALL VENT WITH COMBUSTION AIR FROM EQUIPMENT ROOM The flue outlet terminates out the sidewall The combustion air is drawn from the equipment room BULLET POINTS Category IV vent material is required such as AL29 4C or PVC CPVC All vent joints and seams must be sealed gastight and may not be common vented All vent material fr this configuration including vent termination wil be obtained locally The sidewall termination plate may be used with PVC or GPVG vent material The air is delivered to the equipment room by means defined in Chapter 1 ofthis designer s guide When venting with PVC the first ten feet of pipe must be CPVC lor heat protection See Page 12 o the instalation manual for details VENT VENT VENT MODEL DIAMETER MIN LENGTH MAX LENGTH seN1000 ri 12 SBN1300 7 nr SeN1500 G ET 1006 VERTICAL VENT WITH COMBUSTION AIR FROM THE ROOFTOP The flue outlet terminates on the rooftop The combustion air is ducted to the appliance from outdoors through the rooftop This is true Direct Vent with the flue termination and the air inlet port in the same press
3. zer 7246 sse 210 zo vs we ws 138 Tue ra sa vea s se ss s02 m se aes sa ans er rur aso ism ses em vea 707 eee ese ser sts er aa 2820 2260 1980 1720 160 1 040 1 550 1 280 1 180 ora Zuz sas 4480 3810 a100 2720 2080 231 2100 2000 1 000 1 200 1540 1400 1 300 3 11200 7000 6 400 sao ono 3 500 3540 3300 sno 2720 2500 2340 23 800 16 100 1 100 11 100 10000 9000 750 7380 6 150 5130 2720 The SYNC features Negalive Regulation or Rag gas combustion system The gas is introduced upstream of ha combustion blower As fne lower draws ar in Ine negative pressure on the inlet ol the blower pulis the gas from the gas valve The gasiai mixture is pushed through the blower into the Burner The mixture fiters through the iser burner mesh and is ignited by the spark Igniter On fl fire mostly blue flame risas off the surfaca of the burner As demand decreases the operating control reduces the blower speed and the gas follows Ihe air in proportion The fame is reduced and touches the surface The micro metal foer burner material is designed to burn infra red safely without being damaged by direct contacto the Even at this reduced Blur input the gas ar mixture is balanced to provide clean
4. openings should be sized based on a minimum free area ol one square inch per 2000 11 cms par KW of input 3 COMBUSTION AIR FROM INTERIOR SPACE It air i taken from another interior spac Each ol vn openings ibo should have a net ree area ol inch tor each 1000 22 cm per ot input but not less than 100 square inches 645 om 4 DIRECT OUTSIDE AIR SINGLE OPENING 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 tree area of one Square inch per 3000 Blur 7 em par KW This opening must be located win 12 30 em o the lap ol he Tho combustion air must be ree of any contaminants or chemical fumos Salts refrigerants and solvents introduced Into the combustion process wil result in he formation of corrosive acids that wil damage the appliance and the vent Chapter 2 Venting Venting is another important design element for the installation of gas fred appliance It has a variety of choices many diferent vent configurations to chose rom rules and regulations that govern the instalation and most important of al it bears a requirement for human safety Lochinvar otters five different vent conliguraions on the SYNC boiler to meet Ine requirements They are Vertical Vent with Air trom the Equipment Room Vertical Vent with Air from the Rooftop Vertical Vent wit
5. E 13 SeN1300 EJ est 30 3 20 as 15 37 11 m3 eo 3 3 3s 21 12 17 hassas T Reminder the flow rates and other values listed on the preceding page are for each heat exchanger When combined in common water piping the rates wil double Increase pipe size accordingly Use 3 minimum common mantold pipe size seme Laisa Deci oo ADDITIONAL CIRCULATOR PUMP SPECIFICATIONS 1 Maximum operating pressure for the pump must exceed system operating pressure 2 Maximum water temperature should not exceed the nameplate rating 3 Gast ron circulators may be used in closed loop systems WATER FLOW dr the minimum planned flow rate for the system loop below that of the minimum allowable flow rate through the boiler The lowest potential System Loop Flow Rate MUST b Boiler Loop flow rate 10 greater than the g LOW SYSTEM FLOW RATE In situations where the baller loop is less than the system flow heated water from the boiler wil backleed down the System ine and recirculate back into the boder taking the path of least resistance This means the boiler is recirculating already heated water in a very small volume wisch wil cause the inlet water temperature fo heat up quickly and cycle he boller aff The result isthe building wil not receive the heat and the boller wil short cycle Many modem hydronic heating system
6. PROTOCOL The SYNC features the Smart Tauch control with Modbus prolocol Modbus is a bulding communication language that allows the Building Automation System BAS to converse with the SYNC boller The BAS can monitor and control the operation of the boiler remotely communicating via the Modbus language Note Modbus is an option that must be specified and ordered with each SYNC boiler 27 Modbus is ona of the industries leading communications protocols and can easily couple with other communications protocols through inexpensive gateway device Lochinvar oll preprogrammed gateways for BACnet and LonWorks Via Modbus the BAS can monitor 49 datapoints and adjust another 9 control settings Modbus is easily wired tothe SYNC through twisted pair cable shielded ground Via Modbus the BAS can control the boiler with a simple Enable Disable signal or control through ful Modulation or Setpoint Temperature and wil operate withthe SYNC s buitn Cascade function CASCADE SEQUENCER The Cascade lealue in the Smart Touch control wil operate up to eight boilers Connected with Daisy chain any one baller in the group is chosen as the Leader Tho other boilers operate as Members The Leader boler makes the decison on wich boler and at what fale lo meet the demar Each day a different boller is assigned the role as first in the fring sequence This Lead Lag feature distributes even usage over the Ife of the
7. boilers The Cascade function alsa operates with Outdoor Reset to increase system temperature as the outside temperature decreases Built in Cascade of up to eight boilers SMART TOUCH PUMP CONTROL The Smart Touch control also has the capacity to control tha bailer pumps the system pump and the Domestic Hot Water pumps All pumps aro wired through tho High Voltage Terminal sip All pumps are field supplied The terminal strip is rated for 1 HP pumps maximum For larger horse power pumps plan to insert a switching relay or contactor to decouple the pump from the terminal Sip cantacs Boiler Pump Control The Smart Touch control wil activate and deactivate Ihe two pumps lor each System Heating call fr heat Intermittent pump operation 30 second pump delay programmable System Pump Control The Smart Touch control wil activate and deactivate Ihe pump lor each System Heating cal for heat Intermittent pump operation 30 second pump delay programmable Domestic Hot Water DHW Pump Control The Smart Touch contre wil activate and deactivate the pump foreach DHW cal for heat Intermitent pump operation 30 second pump delay programmable OTHER HIGH VOLTAGE TERMINAL STRIP CONNECTIONS Alarm on Any Failure Contacts Should tne Smart Touch control detect a faut t wil send an alarm signal through these dry contacts to a remote control board or activate an alarm bel Run Time Contacts The Smart Touch contol wil mak these dry c
8. ie unoccupied This is a programmable parameter Service Reminder The Smart Touch contro can display a reminder to the customer that itis time or preventative maintenance This ime frame is a programmable parameter 27 e ADDILTIONAL SMART TOUCH OPERATING FEATURES Open Shorted Sensor Detection Monitoring of Safety Devices Fan Speed Low amp Fan Speed High Ramp Delay Flame Current Support Run Time and Cycle Count Flue Temperature Limiting Temperature Rise Limiting Outlet Temperature Limiting Gradient Limiting DHW versus SH Cycling High Limit Operation Low Voltage Blocking Low Water Protection PC SOFTWARE Allot those features are built inta the Smart Touch contral standard on avery model For easy access to all parameters Lochinvar offers PC Software The PC software program can be downloaded onto a laptop computer and with the connection cable provided in the PC Software Kit you can connect to the PC port on the ECS board on every SYNC control panel SCREEN SHOT OF PC SOFTWARE ee Chapter 6 Other Details of Great Importance STANDARD CODES STANDARD CONSTRUCTION Tha SYNC bailar is design certified to the latest edition of ANSI 221 13 The third party erilication was performed by CSA International and the bollar bears the American Blue Star emblem and the Canadian Blue Flame emblem The heal exchanger Inside Ine boiler conforms 1o the latest edition of the ASME Boiler and Pressure Vessel Code Secti
9. with he latest edition of the National Electrical Code ANSUNFPA No 70 When he unl is installed in Canada i must conform tothe CAE C22 1 Canadian Electrical Code Part and or local Electrical Codes WIRING REQUIREMENTS 4 Al wiring between the appliance and field installed devices shall be made with type T wire 83 35 C sel 2 Al vollage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable 3 The appliance must be provided with proper overload protection Ea TEUCH SMART TOUCH CONTROLS The SYNC features the Smart Touch control The Smart Touch control is designed to operate al the various elements of a hydronic heating system plus Domestic Hat Water The Smart Touch control can operate the boller pump the system pump and the DHW pump Ithas outdoor reset as standard equipment But s best feature Is Cascade the organized coniro ot up to eight separate boilers The Smart Touch control is designed to provide many ol the operating features of a remote Bulding Management System on the boller touch screen display and in its operation Control at your fingertips BUILDING MANANGEMENT SYSTEM CONTROL SYNG boilers are designed to integrate wth Building Management Systems and wil operala via 0 10 VDC input signal to contral the boilers Tho signal can be programmed to call the boilers to fre on a range of modulation or on a temperature range MODBUSB
10. Al necessary sytem equipment may not be illustrated EJ T PAGE SINGLE BOILER WITH HOT WATER GENERATOR The ilustration s for concept only and should not be used for actual installation without engineering or technical advice from a licensed engineer Al necessary system equipment may not be ustated 2 _ PAGE AS DOUBLE BOILERS WITH HOT WATER GENERATOR The ustraton is for concept oniy and should not be used for actual installation without engineering or technical advice from licensed engineer All necessary sytem equipment may not be Ilustrated 7 Appendix B Technical Data and Boiler Component Breakdown SYNC the components the design 1 Access Cover Front The removal o i panels accomplished without toos and provides access to the gas train and th heat exchanger 2 Air Intake Adapter Al for the connacton ofthe air intake pipe t the boiler 3 Air Pressure Switches Tho ar pressure swiches detect blocked flue other vent conditions Air Shrouds 1 0 model only The ar shrouds cool ar and gas ow not baler 5 Automatic Air Vents Each heat exchanger is equipped wih an air vent designed remove rapped air om heat exchanger col 6 Blowers The blower puls ar and gas into the venturi tom 41 Air and gas mix inside the lower and are pushed into the burners Bumer occa and ame appears 360 an Ie uter surace af he
11. General Company and replaced with their own GE Gap code Tha SYNC bailar is factory immed to meet Factory Mutual and GE Gap per standard STATE CODES ADDITIONAL CONSTRUCTION AI states have ther own boiler installation cade but some states have codas hat requiro special equipment on the boiler iset Curren Massachusetts Minnesota and Kentucky have state codes that may require la Lochinvar products Check wih your laca Lochinvar sales office or Lochinvar Customer Service for data DETERMINE THE UNIT LOCATION d Locate the appliance so that i water connections should leak water damage vll nat occur When such locations cannot be avoided iis recommended tha a sulable drain adequately drained be installed under the und The pan must not restrict Combustion Under na cicumstances is the manufacturer la be hald rasponsi for water damage in connection with this unit or any ol its components 2 DONOT instal this applanca in any location where gasoline or Nammable vapors are kely 10 be present 3 The appliance must be installed on level lor Combustible lar locations may be used Maintain required clearances from combustible surfaces 4 The appliance must be installed indoors where tis protected ram exposure o wind rain and weather 5 This appliance may condense the products of combustion i operated at water temperatures below 140 60 C Ensu
12. ODE Look uP gt 8 7 EJ iter ar d 300 Maddox Simpson Parkway Lebanon TN 37090 635 889 8900 fax 615 547 1000 www Lochinvar com sensor Deere cacot pm
13. SYNE CONDENSING BOILER Up ro 98 THERMAL EFFICIENCY Table of Contents iy amp Control Other Details Page 2 Page Page I Page 15 Page 21 Page 29 Page 34 At Lochinvar we know that designing a boiler is hard work Designing a boiler system is no picnic either Demands for greater efficiency and elaborate system control have mado systems more complex This designers quide will break down the system requirements that malch the SYNC boiler to assure safe operation highly efficient heating and long life There are five major elements of boiler system design Combustion amp Ventilation Air See page 2 PM Venting See page 5 Gas See page 13 Water 4 See page 15 Electricity amp Controls See page 21 Plus many other important details Locations Suggested Piping Diagrams Seo page 27 for Location of Unit See Appendix High Altitude Requirements Component List See page 28 for High Altitude Applications See Appendix B Chapter 1 Combustion and Ventilation Air The frst Important design consideration is air Everybody s gotta breathe Evan boilers need ai Air seems easy enough You stand in the equipment room and you breathe comfortably don t you Open a door Open a window This is a big room There s lots of air in here for the boiler fight Tha average person inhales 400 to 500 cubic fet ol air i
14. The vent termination plate tor PVC CPVC venting is supplied withthe boller The vent termination plate for Stainless Steel venting is an optional kit avaiable through Lochinvar The kit part numbers are KIT30028 for 6 termination and KIT30029 for 7 termination lt air is delverad o the appliance via separate duct The alr intake material can be galvanized pipe PVC CPVC or ABS and must be sealed gas iht When venting with PVC the first tan feet of pipe must ba CPVC for heat protection See page 12 of the instalation manual for details TIRINTAKE ARINTAKE VENT VENT MODEL DIAMETER MIN LENGTH MAX LENGTH MIN LENGTH MAX LENGTH seN1000 12 200 seN130 ur Sor nr som seN1300 ur Too te arm SeN1500 ur sore 128 son SeN1500 Too te 1008 VERTICAL VENT WITH COMBUSTION AIR FROM THE SIDEWALL The flue outlet terminates on the rooftop The combustion air is ducted to the appliance from outdoors through the sidewall This is NOT true Direct Vent where the flue termination and the air inlet port are in the same pressure zone BULLET POINTS Category IV vent material is required such as AL29 4C or PVCICPNC All vent joints and seams must be sealed gastight and may not be common vented Al other vent material for is configuration will o obtained locally The vent termination plate or PVC CPVC vent
15. arately you wil want fa design a Primary Secondary piping loop The Primary Loop hereafter reterrad fo as the System Loop flows water around ia building and delvars heat to ha building The Secondary Loop hereafter roferrod as the Boller Loop branches the system loop o water through the bailer and delivar heat to the system The purpose of System Boller Loop piping is lo separato or decouple the system flow rate from the boller Mow rate The System Loop wil have its cwm dedicated pump flowing at one low rate and the separate Bailar Loop will have two dedicated pumps to Towing into and out of the two heat exchangers The Boller pumps are sized based on the head loss of Ine baller and related pipe and fitings in the Boiler Loop only boilers may also be installed with a System Boiler Loop format witha manifold system that connects the mulle bolas o the System Loop Muliple boilers should be connected tothe common manifold in Reverse Return to assit in balancing low mutiple bolers See dagram A4 on page 33 BOILER CIRCULATOR REQUIREMENTS There wil bo a minimum of three pumps in a SYNC System Boiler Loop one pump for the System Loop and two pumps for each heat exchanger in the Bole Loop Al pumps are provided by tha instaler A pump is required on each heat exchanger and must be wired na Ine Boiler control This is required get maximum efficincy out
16. bic loo at sea level Thus the heating value of cubic foot of fuel gas wil decrease as height above sea lave increases Therefore a Tecaicuation al heat input rate should be performed any appliance beginning at 2000 leet Ratings should be reduced at the rate af percent for each 1000 feet above sea leval The SYNC bailar must be factory immed for installation al an altitude range GREATER than Appendix A Boiler Piping Diagrams PAGEAL NEAR BOILER PIPING DRAIN TYPICAL SYSTEM SUPPLY SENSOR NOTICE A SYSTEM SUPPLY SENSOR MUST BE INSTALLED F PROPER BOILER OPERATION SYSTEM PUMP ISOLATION VALVE TYPICAL Y STRAINER RECOMMENDED TYPICAL TEMPERATURE GAUGE MODULE 1 BOILER PUMP RELIEF VALVE MODULE 2 BOILER PUMP CHECK VALVE TO FLOOR DRAIN TYPICAL The i far concept only and should not be used for actual installation without engineering or technical advice from a licenses engineer Al necessary system equipment may not be 30 PAGE A2 NEAR BOILER PIPING WITH LOW LOSS HEADER DRAIN VALVE ISOLATION VALVE TYPICAL MODULE I BOILER PUMP EXPANSION TANK Y STRANER RECOMMENDED TEMPERATURE GAUGE RELIEF VALVE BOILER PUMP TO FLOOR CHECK VALVE TYPICAL The lusation is for concept any and should not be used for actual installation without engineering or technical advice from a licensed engineer
17. buma lo heat into tho exchange This is the locaton rom which the heat exchanger can be drained Inlet Temperature Sensor En heat exchanger ted wi a sensor o monitor return water temperatur rom the boiler syster he controling sensor he conl modula aues the baler rng rt so te inlet temperature matches the Setpoint Boller Outlet Temperature Sensor Each heat exchanger fied i a sensor to monitor supply water temperature going out tothe bole system I Selected as the coriroling Senor e contri module adjusts Ine baller ang rate so he out temperature matches the setpoint 10 Burner Each heat exchanges ed wih a bumer constructed of micro rela fbers and stainless ee The burrs use gas to provide wide ange offing ats rom 20 1o 100 ofthe burners Bute heating 1 Condensate Drain Connection This isa PVC union to connec the drain pipe to the boller The condensate rap calles te condensation from bot heat exchangers 32 Control Modules Two per bler the modules respond to intemal and external signals to conl he combustion process The modios wil contrai the burrs he gaz valvas ne blowers and ine pumps to moet heating demand 13 Electronic Display This is the itat corro of e boller wh touch sere 14 Flame Inspection Window Each heat exchanges iod it a quarz lass window to view the burner surface and the fame 15 Flame Sensors Each heat exchanges od with a
18. exhaust side the building I space is not avaiable the elbows may be installed Even though the SYNC boiler is supplying Vent Termination Plates with pipe ae installed outside the buiding every model Snark el pipe terminations are approved and acceptable roy ani ORATION Alant OR PE DE LOCATIONS AND CLEARANCES P Vertical vent and air intake termination is also approved or tha SYNC baller The exhaust and alr intake terminations may be installed 127 apart minimum side by side or wh the air intake below the exhaust maintaining a 12 seperation Never install Ihe air intake above the exhaust in either rooftop or sidewall termination Ws SJ En Due to the potential or high exhaust temperatures in the event of high water tomporaturs in the system Ie SYNC requies the installation of CPVC pipe forthe fret 10 eet of exhaust pipe may be accomplished with 10 straight feet ol CPVC pipe or with ene 90 CPVC elbow and 5 straight eet of CPVC pipe Do not instal two 90 elbows The sharp changes in direction Cause restriction inthe pipe that exceeds he equivalent length In vent materia AT vent pipe materials and Wings must comply with the following Standards for United States Canada 0 ANSIASTIVOITEG PVC and PVC veni must be ULC SB36 Vent pipe and mings soir vert tera t
19. h Air from the Sidewall Sidewall Vent with Air from the Equipment Room Sidewall Vent with Air from the Sidewall Part I Vent Categories Lochinvar offers tive venting options with the SYNC that must be installed with approved Category IV vent material Below is the vent category diagram standard throughout the industry The four basic Vent Categories are determined by two characteristics Condensation and Pressure n all vent configurations the SYNC boiler wil operate in Category IV The modulation af the burner down to 10 of the bollor s input wil put low temperature lo products in Ihe stack that wil condense The boilers blowers are designed to push the fue products through the exhaust System wih a consistent postive pressure Always use Category IV approved non corrosive vent material and always seal the joints and Connections 100 gas ight in order lo prevent condensation and fue gas leakage 7 VERTICAL VENT WITH COMBUSTION AIR FROM EQUIPMENT ROOM The flue outlet terminates on the rooftop The combustion air is drawn from the equipment room BULLET POINTS designer s guide Category IV vent materia is required such as AL29 4C or PVC CPVC All vent joints and seams must be sealed gastight and may be common vented All vent material fr this configuration including vent Termination wil be obtained locally The air is delivered to the equipment room by means defined in Chapter 1 of this
20. haust fans are popular in equipment rooms to exchange the air 1 the exhaust fan pulls air OUT then a negative pressure occurs in the room The combustion and venation air must be sized to supply al he equipment PLUS tha air fr he exhaust fan COMBUSTION AND VENTILATION AIR SIZING CALCULATIONS Tho sizing calculations in this section based on Free Area The louvers or gril used on the alr openings must have a net Iro area equal to or greater than the value derived in the calculations The Free Area in a louver or gril is defined as the open unblocked area The louvers grils mesh blades ail wil block a given amount of space in the louver s overall dimension Consult the lower manufacturer for exact net rae area of the louver 1 COMBUSTION AIR FROM OUTSIDE I air is taken directly trom outside the building with no duct provide permanent openings tothe equipment room 18 Combustion air opening with a minimum trae area of one square inch per 4000 Btu input 5 5 mper AW This opening must be located within 12 30 em of the bottom of the enclosure b Ventilation air opening with a minimum fre area ot one square inch per 4000 Blur Input 5 8 em per KW This opening must ba located within 12 30 cm ofthe top ofthe enclosure 2 COMBUSTION AIR THROUGH DUCTS 1 combustion and venttion air is taken from the outdoors using duct to deliver the air to the equipment room each ofthe two
21. ing is supplied with the boiler The vent termination plate for Stainless Steel venting is optional kit available through Lochinvar lt air is delivered to the appliance via separato duct The alr intake material can be galvanized pipe CPVC or ABS and must be sealed gas tight When venting with PVC the first ten feet of pipe must ba CPVC for heat protection See Pago 12 of the instalation manual for details ARINTAKE AIRINTARE AIR INTAKE VENT VENT MODEL DIAMETER MIN LENGTH MAX LENGTH MIN LENGTH MAX LENGTH EDI 1001 nr 1008 seN1300 ur sore son seN1300 1008 SaN1500 ur son SaN1500 nr 1008 10 VENT TERMINATIONS SIDEWALL AND ROOFTOP The tue outlet and the air intake pipe may terminate out the sidewall or the rooftop in the patterns shown on pages 6 through 10 Approved vent terminations are shown below The most popular method fora new installation is sidewall venting The Vent Termination Plate and Vent Termination Cap seen in the ilustraon are supplied with every SYNC boder as Standard equipment Prior to the development ofthe Vent Termination plates PVC and sidewall venting was accomplished wih basic and locally acquired plastic fitings This configuration is known as Snorkel piping or Elephant Trunk piping For aesthetic purposes the elbows on the
22. l fre oniy one boller at te reduced input and output rate The minimum 10 output rato of a single SYNC 1000 is 98 000 Btu hr well below the 400 000 Btu hr minimum system demand The SYNG 1000 wil actually fre closer to 42 of its potential modulation rate 19 meet this minimum system demand The tollowing able shows the maximum and minimum i Calculate the minimum load of your design to make sure wil support minimum bole output rate Xu and output rates for every SYNC Ihe system demand or system volume HERON ROT MODEL NUMBER INPUT OUTPUT INPUT OUTPUT 7 000 000 90 000 300096 28 000 1300000 1248000 130000 124700 ESTIS 1500000 31470000 150 000 147000 I the minimum Btu system demand is SMALLER than the boller minimum Btu hr output then there may be insufficient water volume I that is the case then a Buller Tank should be Used BUFFER TANK Tha Buffer Tank adds water volume to the system providing the volume needed to support the minimum output rate of the boller and keep the boiler short cycling 20 Chapter 5 Electrical amp Controls The first consideration is to supply power to the boiler A 120 VAG 15 Amp 1 ph 60 Hz circuit is required fr operation of he boller Tho boiler when installed must ba electrically grounded in accordance with Ye requirements of the authority having juriedieton orn tha absence of such requirements
23. less Steel Heat Exchanger Teo par bler those are ne ASME pressure vessels at wil contain the combustion process Each h feares stainless so cols ina primary chambar and a secondary chamber for maximum heat anser 38 Temperature and Pressure Gauge Monkors a cult watar temperature and the ott water pressure 39 Test Switch Tast switch or he Low Water Cut Of Hold for 10 seconds to tast 40 Top Panel Removable pane to gain acess to the intemal components A1 Venturi One on ach blower the venturi controls air and gas ow into the burners 42 Water Inlet Connections Two per boler these are 2 NPT water connections for incoming water fw into each heat exchanger 43 Water Outlet Connections Gre per boler this ia 3 NPT water connection for hat water Bowing aut the system exchanger SYNC 1000 1500 Rear View Loft Side inside view Right Side inside view Go to wi Jochinvar com for mare information on all Lochinvar products This is a screen shot ofthe SYNC webpage Fram the home page click the Ballers button on the eft side of tha page This takes you to new page listing all the Lochinvar product familles Click on the SYNG in the op row In this SYNC webpage you vil be able to download the Installation Manual he Service Manual the SYNG Brochure Piping Diagrams Plan View Drawings and much more M
24. n a 24 hour period one milion Bluhr bolle wil draw 226 38 cubic teet of air every MINUTE A 20 by 20 by foot equipment room holds 3200 cubic feet of air That s a volume of air to tast you or me over six days one milion SYNC wil consume 3200 cubi fat of air in 14 minutes Therefore a good easy flow of clean air is 100 necessary for clean efficient combustion So we need to provide a permanent and uninterrupted flow of air to the boiler The SYNC boiler is designed to receive combustion air by ane of TWO methods The boiler may draw combustion aie rom the roam or have the air ducted deci to the boiler an exterior space This chapter explains the methods for air from the room Chapter 2 explains ai ducted directly to the boiler Again this chapter ists several techniques to size the air openings that wil deliver room air I there are other appliances inthe room requiring ther requirements must be including when sizing the air openings Provisions fer combustion and ventilation air must be designed and installed in accordance with Ar fr Combustion and Venta o the latest edition af the National Fuel Gas Code ANSI 2223 1 n Canada the latest ection of CGA Standard 8149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions ofthe local building cades NEGATIVE PRESSURE IN THE EQUIPMENT ROOM tis important to NEVER have a negative pressure on the equipment room Ex
25. o each exchanger when fired separately In addition tothe two pumps check valves are required to reduce the potential for water recirculation when only one pump is owing Also Wye Strainers are recommended lo remove particles from tha piping system that could damage the heat exchanger and cause non warrantable failure The stainless steal colis inside the heat exchanger are small and can become lagged If there is loose debris loafing in the water piping 16 Wye Strainers Pump 1 Check Valves Typical Pump To Drain The boder pumps must be sized to provide adequate flow through the boiler and the Boiler Loop piping A pressure drop chart is provided to assis in proper pump selection tha char ists the values for EACH heat exchanger This lable provides GPM and boiler head oss at various temperature rises for each model based on Biur input Pipe diameter and length are crcal o enste proper law through the Boller From the table choose the temperature tise and the low rate for best operation at the boller Fere Drop va Flow ae 4 BH Hj HM EZ H e K ped i AF Ti ET How Rate GPM Single Hent Exchanger Only TEMPERATURE RISE APPLICATIONS Minimum Pipe 20 F 25 Ex Mode Size ew reo Gem rw cem rro cpm rimo ss 3 4 2 ss 18
26. od V ULC 896 Pie comentpremer estera Ex TNSUASTM FOS NOTICE DO NOT USE CELLULAR FOAM CORE PIPE 12 Chapter 3 Gas Supply Lochinvar products are designed withthe concept a lame control We develop combustion systems that tightly control the flow of air and gas to deliver clean and efficient bum In Chapters 1 and 2 we showed the various methods deliver an ampla quantity ol air to the appliance In Chapter 3 we discuss delivering steady and reliable supply of gas to the appliance The key to the gas supply is sizing the gas Ine properly rom the meter to the baller The SYNG will require less than a half a pound of pressure The following Sizing Chart is based on less than apound of pressure or lass than 14 Inches of water column The table is derived from the ANSI 22231 the National Fuel Gas Code Simply calculate the total near foot ot straight gas pipe Figure each elbow as equal to five Straight leet of pipe Working down the column thal maichee your pipe length find the value GREATER THAN the total Bu hr input of the boiler or boilers This wil identify the minimum nominal iron pipe size GAS FIPE SIZNG GHART Nominal on Length of Pipe in Straight Foot Pipe s o m 3 3 5 75 9 s wes 39 vs se ae 256 208 va ves er ss er ws we os s 79 74 v er amr asa s28 202
27. on IV and the vessel bears the ASME H Stamp The installation ot heating boiler is governed by local boiler codes The boiler shall be installed in accordance with those instalation regulations and shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before instalations are made The local code may require a feature on the boller above and beyond the ANSI requirements Review the local code especially in regard to the venting requirements Inthe absence of local codes U S installations shall conform to the latest edition of the National Fuel Gas Code ANSI 2223 1 In Canada the installation must comply wih the Canadian Gas Association Code 8149 1 andior B149 2 and or local codes GSA International CSA Intemational ASME Section IV Blue Star for United States Blue Flame for Canada H stamp for Boilers OPTIONAL CODES ADDITIONAL CONSTRUCTION Many local authors require the boiler installation conform to 601 the American Society of Mechanical Engineers Salety Code far Controls and Safety Devices for Automatically Fired Boilers CSD 1 is subject to diferant interpretation by diferent boiler inspection offices The SYNC bailar is factory immed to meet CSD 1 code per standard interpretation Factory Mutual is an insurance driven code and the SYNC boiler must be factory trimmed meet Factory Mutual The well known Industral Risk Insurers code has been purchased by
28. ontacts tor the duration of the Main LOW VOLTAGE CONNECTION BOARD Every SYNC is equipped with a Low Voltage Connection Board for a variety ot other fid connections and control features Remote Enable Disable Wired through he Low Voltage Terminal Sirip the Smart Touch control can be activated by remote Thermostat or controlled wih an enable disable signal Domestic Hot Water DHW Mode via Sensor or Thermostat The Smart Touch contro wil operate the DHW based on a signal rom a tank sensor with a resistance signal or a tank thermostat with an enable disable signal Louver Contacts The Smart Touch control wil open and close equipment room louvers a cal for heat with Louver Proving Switch lor control safety 27 Flow Switch Flow Switches aro not required due to the boilers built in LWCO and Low Water Temperatura Protection programming However contacts are provided for feid installation of Flow Switches If required by state or local jurisdiction BMS Control with 0 10 vde Input The Smart Touch contro can be activated by a Building Management System with a 0 10 Vdc signal The signal can control either the setpoint or the modulation directly It can conto a single boiler or multiple boilers through Cascade Domestic Hot Water DHW Tank Sensor When a sensor is mounted in the Domestic Water Storage tank the Smart Touch will operate the DHW from this sensor System Supply Sensor system sensor must be mounted in the
29. pressing against the appllance gas rain with excessive system pressures This can damage the components in Ihe gas tai 14 Chapter 4 Water Water tow water temperature and water volume in modem hydronic heating systems are all elements of system design that need Io bo carefully planned Today s high efficiency low mass heating boilers requir a closer lock at these design parameters in order to maximize the and the of he appliance low rol ort gh each heat ex There are three major concepts to consider when designing the near baller piping system They are WATER FLOW WATER TEMPERATURE WATER VOLUME A boller or bank of boilers has a given range of operation under these three concepts A boier has a water fow rate range water temperature range and water volume range 1 you design system that lets the boder operate within its comfort zone it performs efficientiy and wil have a good expectancy I the system lorces the boller fo operate outside any one of Ie tives comfort zones Ihe boiler suffers WATER FLOW Minimum and maximum Flow Rates must be maintained per the design parameters of the boiler Does the maximum planned flow rate for the system loop exceed the maximum allowable flow rate through the boiler The maximum flow rate for the SYNC 1000 1500 models is 90 GPM per heat exchanger 18 Because system rates and boller low rates need to be controlled sep
30. r nese devises monitor the utet water temperature I te water temperature exceeds the seting cf e switenes shut of operation 26 Ignition Electrodes Each bumer is ited wih an electrode to provide direct sparkignton of the gas air mur 27 Line Voltage Junction Box This ington bae provides cannecton points or ina votage power and connection to all the pumps 28 Line Voltage Wiring Connections Knockouts Conduit connecten to the igh voltage junction boc 29 Low Gas Pressure Switch One par ber ow gas switch protects he boiler rom fring wih low gas pressure 30 Low Voltage Connection Board This connection board proves various connections to saleties and oiher extemal ow voltage devices 31 Low Voltage Wiring Connections Knockouts Condit connection the tw voltage junction ben 32 Low Water Cut Off device LWCO Device used ta ensure adequate water is to he boiler and in the event of inadequate waler levels wil shut cf bumer operate 33 Power Switch Rocker swin 120 VAC ON or OFF tothe boiler 34 Pump Relay Board The pump relay boards are usd o connect the boller pump the system pump and the Hot Water Generator pump in wih the sequence o operation of the boller 35 Reli Valve Protects tho heat exchangers rom over pressure conditions The standard reel valve is set tor 50 ps 26 Reset Switch Reset s te forthe Low Water Cut Of Hold for 10 seconds to reset 37 Stain
31. re that the appliance is located near an acceptable drain where condensate that may form inthe venting system can be properly collected and disposed 6 Access to the rear of he appliance MUST be maintained an gpa er are Le Se Mirum 26 pet fr anser 3 JMrimum 20 sugestos or seen Closet Installation Alcove Installation 27 CONDENSATE TRAP Tha SYNC is fitted with a condensate trap o be feid mounted on the floor behind the appliance The isa requirement of the ANSI standard fr any Category V ented appliance wth condensation forming in tha stack Ino neutralization kit i installed the condensate trap must be piped to a drain NEUTRALIZATION KIT Tho SYNC wil produce condensate as heat is transferred from the fue produces into heat exchanger This condensate wil have pH imbalance of 2 or 3 pH In Some areas condensate may not be placed into the drainage or Sewer system unless is has been returned io a relatively normal pH level For this purpose Lochinvar salis KIT3046 an optional neutralization kit Installed as Seen in the figure the kit wil bring the condensate back toa pH level near 7 pH HIGH ALTITUDE APPLICATIONS Atmospheric pressure dacreases as the height above sea level increases At any above level a cubic foot contains less gas than a cu
32. s are designed to vary the flow rate in the system loop as an energy eftiency measure Tha system pumps can provide proper iow forthe heat distribution system by measuring the pressure diferential om the system and providing just enough low to march the requirements of the heat emitrs that are caling for heat at that spect time When a system is designed with a Variable Frequency Drive he system pumps precautions must be taken to very that the baller loop flow rate wil not be greater than the system loop rate Additionally the use of 3 way valves on the heating system to raset the system loop temperature Wil cause the llow rate to vary through the boller When using a low mass boiler such as the SYNC 3 way valve used or system loop temperature reset must be avoided or the boiler shouid bo decoupled from the system loop with the use of a Buffer Tank or a Low Loss Header Buffer Tank is preferred BUFFER TANK OR LOW LOSS HEADER A Butler Tank or Low Loss Header solves this problem These devices add water volume at the point where the System Loop and the Boller Loop meet Classic System Boiler Loop piping isolates the flow rates well but a Butler Tank or Low Loss Header wil isolate the rates completely and add water volume o provide more effective decouple far the boler WATER TEMPERATURE Water temperature also needs be taken ino consideration What is the return water temperature from the S
33. sensor monitored by he control module to datect the presence of the baner ame 16 Flap Valves Each heat exchanger is od witha ap valve designed prevent the recirculation of fue produces when one burner inane heat exchanger hing and aner bumer inte ner heat exchange at rest 7 Flue Gas Sensors Each heat exchanger s fited wi a ue gas sensor The sensor s monitored by the contol module to maintain fue gas temperature and protect the pipe om vere 18 Flue Pipe Adaptor Provides for connecton of PVC vent materia 1o the baller 18 Gas Connection Pipe A singe 1 1 2 NPT headed black pipa connection for incoming gas supp 20 Gas Shut Off Valve Inside the boiler Downstream o each gas valve i manual valve provided 1o stap the fow of gas to the venturi for test purposes in technology and ut color display 21 Gas Shut Off Valve Outside the boiler valve provided to scite baller from the of incoming gas supply Combinaton gas valves one on each heat exchanger Operating on negative air pressure ram he blower ales allow gs ow any the valves are powered and the combustion ar i owing 23 Heat Exchanger Access Cover 1 access 1o he combustion side of he heat exchanger coils 24 High Gas Pressure Switches Teo per ballar the igh gas switches protect he bailer trom fring with an exces of gas pressure 25 High Limits One per heat exchange
34. supp Jy line of the primary system loop When Smart Touch is programmed to operate ha outlet sensor default setting and the system supply sensor is connected wil control the firing ale based on this sensor This sensor MUST always bo installed Outdoor Air Reset with Outdoor Sensor When the outdoor air sensor is Installed the Smart Touch control wil adjust system temperature based on the outdoor ar temperatur SMART TOUCH OPERATIONAL FEATURES The following is a ist of just a few of the many other operational features bul in to tha Smart Touch control For the complete ist of features with more detailed explanations plus programming parameters rele to the Installation Operation Manual the Service Manual or the User Manual Clock The Smart Touch has a clock for dala and lime This must be sel for record keeping and night setback functions Domestic Hot Water DHW Priority On a DHW cali heat the Smart Touch control will interrupt a SH cal tor heat otf the boiler pumps and tuming on the DHW pump Freeze Protection The Smart Touch control automatically monitors the water temperaturas and wil operate the pump and it necessary Iire the appliance to protect the heat exchanger freezing Anti Cycling The Smart Touch control wil monitor burn cycles and force a minimum otf time to reduce short cycling Night Setback The Smart Touch will reduce the SH or DHW setpoints during periods where the building
35. ure zone BULLET POINTS Category IV vent material is required such as AL29 4C or PVCICPNC Al vent joints and seams must be sealed gastight and may not be common vented lt other vent material for ths configuration including vent termination wil bo obtained focally The air is delivered to the appliance via separate duct The lr intake material can be galvanized pipe PVG or ABS and must be sealed gas tight When venting with PVC the first ten feet of pipe must ba CPC for heat protection See Page 12 at the installation manual for details ARINTAKE ARINTAKE INTAKE VENT VENT MODEL DIAMETER MIN LENGTH MAX LENGTH MIN LENGTH MAK LENGTH SeN1000 EDI 1001 1008 SeN1300 EI EIS SeN1300 on EI 1008 SaN1500 EIS SaN1500 EI 1008 SIDEWALL VENT WITH COMBUSTION AIR FROM THE SIDEWALL The flue outlet terminates on the sidewall The combustion air is ducted to the appliance from outdoors through the sidewall This is true Direct Vent with the flue termination and the air inlet port in the same pressure zone gt gt BULLET POINTS Category IV vent material is required such as AL29 4C or PVCICPC All vent joints and seams must bo sealed gastight and may not be common vented Al other vent material for is configuration will o obtained locally
36. ystem Loop The minimum return water temperature to the SYNC boiler is 40 F 4 440 The SYNC operates more effletly the lower he retum water temperature is it enters the baller Therefore deal condensing operation will be achieved at temperatures Below 140 ie colder the better Temperatures below 100 F will elver thermal elficlencies al 98 and above WATER VOLUME tis important to keep an amount of water In the system to support the heating capacity of the boller during the lowest possible demand What is the minimum Btu hr system demand The minimum system demand must be GREATER than the minimum boiler output Tha SYNC boiler has a 10 1 Turndown ratio Or a minimum Btu output rate down to 10 ot the heater total output rate This wil greatly increase the bollors Blur ability o match the system demand Example Imagine an instalation consisting of ive air handlers with 400 000 Blulhr rated heating coils for a totai demand of 2 000 000 Blur system demand The system is heated by two SYNC 1000 beis for a total input of 2 000 000 Btu hr Each bailer i the standard model that fres at 10 1 Turndown On a very cold winter day all ive ar handlers wil call or heat and both SYNG boilers wil fre at 100 input rate to meet demand On a comparatively cool autumn day only one 400 000 Btu h alr handler might be calling for heat The boilers connected together with their Smart Touch controls wi
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