Table of Contents
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Service Manual
Models: 1.0, 1.3, and 1.5
This manual must only be
WARNING
used by a qualified heating
installer / service technician.
Read
including this manual and
the SYNC Installation and
Operation Manual, before
installing. Perform steps in
the order given. Failure to
comply could result in severe
personal injury, death, or
substantial property damage.
Save this manual for future reference.
SYNC-SER Rev H
all
instructions,
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Table of Contents
Troubleshooting
Related Manuals for Lochinvar Sync Condensing Boiler 1.3
Summary of Contents for Lochinvar Sync Condensing Boiler 1.3
- Page 1 SYNC-SER Rev H Service Manual Models: 1.0, 1.3, and 1.5 This manual must only be WARNING used by a qualified heating installer / service technician. Read instructions, including this manual and the SYNC Installation and Operation Manual, before installing. Perform steps in the order given.
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Page 2: Table Of Contents
Contents Parameter Table............11-12 CONTENTS ................ 2 Viewable and Changeable Control Parameters ..13-35 Hazard Definitions .............. 2 2. MAINTENANCE PLEASE READ BEFORE PROCEEDING ......2 Maintenance and Annual Startup ........ 36-41 Handling Ceramic Fiber Materials ........3 3. TROUBLESHOOTING When servicing boiler ........... -
Page 3: Handling Ceramic Fiber Materials
Service Manual Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can WARNING be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”... -
Page 4: What Is In This Manual
Service Manual What is in this manual? Service Maintenance Near boiler piping • Service and maintenance schedules • Address reported problems • Typical system components • Inspect boiler area and boiler interior The SMART TOUCH display • Clean condensate trap •... -
Page 5: Service Near Boiler Piping
Service Manual Service Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the SYNC. This piping scheme is important for proper operation of the SMART TOUCH control module. See the SYNC Installation and Operation Manual for more detailed piping diagrams. -
Page 6: The Sync Boiler Display
Service Manual Service The SYNC display... -
Page 7: Control Inputs
Service Manual Service (continued) Control inputs SECONDARY SMART CONTROL LOW VOLTAGE CONNECTION MODULE BOARD PRIMARY SMART CONTROL MODULE SEQUENCER / BUILDING MANAGMENT SYSTEM O-TEMP OUTDOOR SENSOR HEAT EXCHANGER SWITCH HW TANK SENSOR PRIMARY/SECONDARY INLET TEMPERATURE SENSOR SYSTEM SENSOR O-TEMP HEAT EXCHANGER SWITCH PRIMARY/SECONDARY OUTLET TEMPERATURE SENSOR FLOW SWITCH... -
Page 8: Control Outputs
Service Manual Service Control outputs SECONDARY SMART TOUCH LOW VOLTAGE CONTROL MODULE CONNECTION BOARD PRIMARY SMART TOUCH CONTROL MODULE ALARM BELL RUN TIME CONTACTS HEAT EXCHANGER 1 / HEAT EXCHANGER 2 BOILER PUMP SEQUENCER / BUILDING SYSTEM PUMP MANAGEMENT SYSTEM TOUCH PANEL HW PUMP TOUCH DISPLAY... -
Page 9: General Operation
Service Manual Service (continued) General Operation How the boiler operates Access modes The SYNC uses two (2) advanced stainless steel heat User exchangers and two (2) electronic control modules that allow fully condensing operation. The blowers pull in gas and air The user can view all of the settings on the LCD screen. -
Page 10: Sequence Of Operation
Service Manual Service Sequence of operation Table 1A Sequence of operation - space heating and HW Note: This unit is equipped with two (2) independent, but synchronized combustion systems. Heat Exchanger 1 (top) 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. -
Page 11: Parameter Table
Service Manual Service (continued) Parameter table Table 1B This table lists the parameters and where to access them USER ACCESS INSTALLER ACCESS MENU DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY Service/Setup Night Setback Set points Cascade Outdoor Reset Pumps Demand Conf Serv Not Time Serv Not Run H Serv Not Cycl... - Page 12 Service Manual Service Table 1B (continued from previous page) This table lists the parameters and where to access them USER ACCESS INSTALLER ACCESS MENU DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY Reset T Lo Out Reset T Hi Out Out T Hi Reset Out T Lo Reset Out SD setp Out SD df...
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Page 13: Viewable And Changeable Control Parameters
Service Manual Service (continued) Viewable and changeable control parameters Status Screen: 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. - Page 14 Service Manual Service Hot Water Tank Temperature - This is the temperature as Boiler Configuration - This line shows the current measured by the tank sensor in the hot water storage tank. configuration of the two control modules inside the unit. Time - The time is displayed in the upper right-hand corner of Outlet Water Temperature - This is a calculated temperature the display.
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Page 15: Details Screen
Service Manual Service (continued) Details Screen: • Alarm - Is ON when a fault has been detected and the The Details Screen is accessed by pressing the DETAIL button alarm contacts are closed. Is OFF when the alarm on the Status Screen. This screen shows the status of the contacts are open. - Page 16 Service Manual Service Time - The time is displayed in the upper right-hand corner of A blank message box is located on the Details Screen. This the display. It is displayed in 24 hour format. Reference the box will display various messages detailing the status of the night setback parameters on page 24 for information regarding control module.
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Page 17: Main Screen
Service Manual Service (continued) Main Screen: The Main Screen allows navigation to eight (8) additional Navigation to the Main Screen can be accomplished by pressing screens which are used to set temperatures, operating the MAIN button at the bottom of the page. conditions, and monitor boiler operation. - Page 18 Service Manual Service Before changing parameters, note the settings so that the unit can be returned to its original operating CAUTION parameters. Setup Screen: The Setup Screen allows access to seven (7) other screens for If the password has been entered correctly, the Parameter adjusting control parameters.
- Page 19 Service Manual Service (continued) Service/Setup Parameters Screen: The Service / Setup Screen allows access to 10 parameters. If either BMS configuration is selected, additional parameters Those parameters are as follows: for BMS operation will have to be adjusted. Reference the BMS parameters on pages 27 and 28 for information •...
- Page 20 Service Manual Service Reference page 18 for information regarding changing • Maximum Service Time - Service Mode allows the parameters. installer to control the fan speed of the individual control modules for the purposes of combustion analysis. Time - The time is displayed in the upper right-hand corner of Service Mode will override all other heat demands, the display.
- Page 21 Service Manual Service (continued) Set Point Parameters Screen: The Set Point Screen allows access to 12 parameters. Those The user or installer may not go below this parameters are as follows: value when programming the “User Set Point”. temperature range of this parameter is 0° to 190°F. The •...
- Page 22 Service Manual Service Outdoor Reset Parameters Screen: When the outdoor air sensor is installed, the control will • Outdoor Temperature at Low Reset Temperature - When the outdoor air temperature rises to or above this point, the calculate the water temperature set point based on the water temperature will be at its minimum setting.
- Page 23 Service Manual Service (continued) • Boost Increment - If a system heat call last longer than the programmed boost time setting and there have been no Hot Water Generation calls, the control will increase the water temperature set point by the amount in this parameter. If the system heat call continues through another time period, the set point will be increased again.
- Page 24 Service Manual Service Night Setback Parameters Screen: The Night Setback Screen allows access to 15 parameters. Example: Monday ON: 22:30, Tuesday OFF: 6:45. If you wish Those parameters are as follows: to skip a day and no night setback is necessary, program the on and off times the same and set them prior to 12:00 (noon).
- Page 25 Service Manual Service (continued) Cascade Parameters Screen: • Cascade Off/On Differential - Sets how many degrees Cascade Operation below the turn off temperature (set point + Cascade Off When multiple boilers are installed, they can be wired Differential) the temperature has to go before the lead together in a cascade sequence.
- Page 26 Service Manual Service Pumps Parameters Screen: Time - The time is displayed in the upper right-hand corner of The Pumps Screen allows access to four (4) parameters. the display. It is displayed in 24 hour format. Reference the Those parameters are as follows: night setback parameters on page 24 for information regarding •...
- Page 27 Service Manual Service (continued) 0 - 10Vdc BMS Parameters Screen: ModBus Timeout 0-10Vdc Operation • BMS Voltage at Minimum Set Point - Determines the When the Demand Configuration parameter (see page 19) voltage at which the external signal begins to increase the is set to either Cascade BMS Thermostat Based, Cascade set point.
- Page 28 Service Manual Service ModBus Timeout Reference page 18 for information regarding changing • BMS Modulation at Minimum Voltage - Determines the modulation rate of the unit or cascade when the BMS parameters. input voltage is at or below the setting of the BMS Voltage Time - The time is displayed in the upper right-hand corner of at Minimum Modulation parameter.
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Page 29: Cascade Screen
Service Manual Service (continued) Cascade Screen: System Temperature - This is the water temperature as measured The Cascade Screen provides the status of the cascade system. by the system sensor located in the system supply piping. Items that can be viewed on the Cascade Screen are as follows: SH Set Point - This is the set point of the cascade system. - Page 30 Service Manual Service The Building Screen displays information that is specific to the Building Automation System and is being transmitted through the Modbus communication link: Modbus Address - This is the address of a specific SYNC Boiler Command - This displays the value written to register boiler.
- Page 31 Service Manual Service (continued) Temps Screen: The Temps Screen displays the various temperatures as Time - The time is displayed in the upper right-hand corner of measured by sensors connected to each control module. the display. It is displayed in 24 hour format. Reference the Items that can be viewed on the Temps Screen are as follows: night setback parameters on page 24 for information regarding adjusting the date and time.
- Page 32 Service Manual Service Burners Screen: This screen provides the status of the combustion air blowers Time - The time is displayed in the upper right-hand corner of and flame signals. Items that can be viewed on the Burners the display. It is displayed in 24 hour format. Reference the Screen are as follows: night setback parameters on page 24 for information regarding adjusting the date and time.
- Page 33 Service Manual Service (continued) Graph Select Screen: The Graphs Screen consists of two (2) different screens. The Time - The time is displayed in the upper right-hand corner of first screen is the Parameter Selection Screen. By pressing the the display. It is displayed in 24 hour format. Reference the box beside the desired item, a check will appear in the selected night setback parameters on page 24 for information regarding box and the control will graph the status of that item.
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Page 34: History Screen
Service Manual Service History Screen: The History Screen shows the status of various counters Time - The time is displayed in the upper right-hand corner of and faults for each control module. Selection of the control the display. It is displayed in 24 hour format. Reference the module to be viewed is accomplished by pressing the SELECT night setback parameters on page 24 for information regarding button. - Page 35 Service Manual Service (continued) Service Mode Screen: The Service Mode Screen allows the individual control Time - The time is displayed in the upper right-hand corner of modules to override all other heat demands and operate at the display. It is displayed in 24 hour format. Reference the a full fire condition for the purpose of combustion analysis.
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Page 36: Maintenance
Service Manual Maintenance Maintenance and annual startup Table 2A Service and Maintenance Schedules Owner maintenance Service technician (see the SYNC User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems • Check boiler area •... -
Page 37: Address Reported Problems
Service Manual Maintenance (continued) Follow the service and maintenance procedures given throughout this manual and in component literature WARNING 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. -
Page 38: Check Expansion Tank
Service Manual Maintenance Flue vent system and air piping Safety relief valves should be re-inspected WARNING AT LEAST ONCE EVERY THREE YEARS, Visually inspect the entire flue gas venting system and air by a licensed plumbing contractor or piping for blockage, deterioration or leakage. Repair any authorized inspection agency, to ensure joints that show signs of leakage. -
Page 39: Check Burner Flame
Service Manual Maintenance (continued) Inspect ignition and flame sense Check burner flame electrodes 1. Inspect flame through observation window. 1. Remove the ignition and flame sense electrodes from the 2. If the flame is unsatisfactory at either high fire or low fire, boiler heat exchanger access cover. -
Page 40: Check Flame Signal
Service Manual Maintenance (continued) Check flame signal 5. Remove the condensate hose from the heat exchanger end. Connect a field supplied 3/4” diameter hose to a drain pan. Using field supplied means, cover the refractory in the back 1. At high fire the flame signal shown on the display should of the combustion chamber of the heat exchanger. - Page 41 Service Manual Maintenance Test low water flow conditions 10. Restrict the isolation valve until both control modules have shut down. If both control modules have been shut down, This test is to be carried out once the the test was successful. NOTICE SYNC boiler is completely piped in 11.
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Page 42: Troubleshooting
Service Manual Troubleshooting Alarm Screen: Reset button - The RESET button must be pressed to reset an If a fault occurs which requires a Manual Reset, the unit alarm. Once the button is pressed, the Reset Confirmation will go into a lockout condition and the Alarm Screen will Screen appears. -
Page 43: Before Troubleshooting
Service Manual Troubleshooting (continued) Label all wires prior to disconnection Figure 3-1 Control Module Fuses WARNING when servicing controls. Wiring errors can cause improper and dangerous operation. F3 - 1.25 AMP FUSE Always disconnect power to the boiler MAIN BOARD before servicing. -
Page 44: Table 3A - Troubleshooting Chart - No Display
Service Manual Troubleshooting Table 3A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION - No 120 VAC supplied to unit. • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. •... -
Page 45: Checking Temperature Sensors
Service Manual Troubleshooting (continued) Checking temperature sensors The boiler temperature sensors (inlet water, outlet water, system water, flue, and outdoor air) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature. -
Page 46: Table 3E - Troubleshooting Chart - Noisy System
Service Manual Troubleshooting Table 3E Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply gas problem. Natural gas pressures • Refer to Section 6 - Gas Connections of the SYNC should be between 4 inches w.c. (1.0 kPa) Installation Operation Manual... -
Page 47: Table 3F - Troubleshooting Chart - Fault Messages
Service Manual Troubleshooting (continued) Table 3F Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check boiler pump operation on a call for heat. • Check for closed valves or obstructions in the boiler Flow Switch/ piping. -
Page 48: Corrective Action
Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • If 24 VAC is present at the main control board, check the wiring between the main control board and the gas valve. - Page 49 Service Manual Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • If 24 VAC is present at the main control board, check the wiring between the main control board and the gas valve.
- Page 50 Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Automatic Reset High Limit: • Verify that the system is full of water and that all air has been properly purged from the system. •...
- Page 51 RESET button on the display to reset.) Sensors equipped with an internal limit (such • Check the tank temperature. as the Lochinvar Squire ® Indirect Tank), the Tank Open • Repair or replace the sensor wiring if damaged.
- Page 52 Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Air pressure switch contacts are open. • Check the wiring connections to switch. Wires should be connected to the common and normally closed terminals.
- Page 53 Service Manual Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The main control board has detected an • Replace the main control board. Internal Fault internal fault. Writing to The main control board has detected an •...
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Page 54: Combustion Analysis Procedure
Service Manual Troubleshooting Combustion Analysis Procedure Table 3H Flue Products 1. Turn the main power off to the boiler by placing the Natural Gas Propane “On/Off” switch in the OFF position. 2. Remove the flue temperature sensors from the flue pipe connections. -
Page 55: Gas Valve Adjustment Procedure
Service Manual Troubleshooting (continued) Gas valve adjustment procedure Models 1.3 - 1.5 If adjustment of the gas valve is deemed necessary, use the Locate the throttle adjustment screw on top of the gas valve, following procedures: (Note: The procedures below are see FIG. -
Page 56: Revision Notes
Revision Notes: Revision A (ECO #C02428) initial release. Revision B (ECO #C03046) reflects changes made to the History, Details, and Graphs screen shots (pgs. 15, 33 and 34). Revision C (ECO #CO2918) reflects the addition of Tank Sensor Open on page 50. Revision D (ECO #C04062) reflects changes to the terminology in all SYNC manuals and labels from module to heat exchanger (exception: control module), edits made to the ceramic fiber material warning,...