Lochinvar SYNC 1 Service Manual
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Lochinvar SYNC 1 Service Manual

Lochinvar SYNC 1 Service Manual

Condensing boiler
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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 G
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Summary of Contents for Lochinvar SYNC 1

  • Page 1 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.

  • Page 2: Table Of Contents

    Gas Valve Adjustment Procedure ... 55 Revision Notes ... Back Cover When calling or writing about the boiler NOTICE – Please have the boiler model and serial number from the boiler rating plate. Consider piping and installation when determining boiler location (see the SYNC Installation and Operation Manual).

  • Page 3: Handling Ceramic Fiber Materials

    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.

  • Page 4: What Is In This Manual

    • BMS Maintenance • Service and maintenance schedules • Address reported problems • Inspect boiler area and boiler interior • Clean condensate trap • Check all piping for leaks • Check air openings • Flue vent system and air piping •...

  • Page 5: Service Near Boiler Piping

    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 (continued) Control inputs LOW VOLTAGE CONNECTION BOARD SEQUENCER / BUILDING MANAGMENT SYSTEM OUTDOOR SENSOR HW TANK SENSOR SYSTEM SENSOR FLOW SWITCH HW THERMOSTAT ROOM THERMOSTAT / ZONE CONTROL PRIMARY SMART CONTROL MODULE O-TEMP HEAT EXCHANGER SWITCH BLOCKED DRAIN SWITCH LOW WATER CUTOFF TOUCH PANEL INTERFACE...

  • Page 8: Control Outputs

    SEQUENCER / BUILDING MANAGEMENT SYSTEM TOUCH DISPLAY PRIMARY SMART TOUCH CONTROL MODULE SYSTEM PUMP TOUCH PANEL INTERFACE PC INTERFACE Service Manual SECONDARY SMART TOUCH CONTROL MODULE HEAT EXCHANGER 1 / HEAT EXCHANGER 2 BOILER PUMP HW PUMP IGNITOR BLOWER GAS VALVE...

  • Page 9: General Operation

    (2) electronic control modules that allow fully condensing operation. The blowers pull in gas and air and push flue products out of the boiler through the heat exchangers and flue piping. The control modules regulate blower speeds to control total boiler firing rate. The gas valves sense the amount of air flowing into the boiler and allow only the right amount of gas to flow.

  • Page 10: Sequence Of Operation

    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).

  • Page 11: Parameter Table

    Service (continued) Parameter table Table 1B This table lists the parameters and where to access them MENU DESCRIPTION Service/Setup Night Setback Set points Cascade Outdoor Reset Pumps Demand Conf Serv Not Time Serv Not Run H Serv Not Cycl Ramp Delay Max Serv T Temp Unit User Passwd...
  • Page 12 Date and time On Timer and Off Timer Casc Address Casc off df Casc off/on df Max Outl temp Boiler Pump D HW Pump D Sys Pump D Sys Pump mode BMS Type BMS Setp min V BMS Setp max V...

  • Page 13: Viewable And Changeable Control Parameters

    • Standby - The boiler has not received a system call or hot water generation call. • SH Call for Heat - The boiler has received a system heat call. • SH Pump Delay - The boiler has satisfied a system heat call and the boiler pumps are running for a fixed time to remove any residual heat.
  • Page 14 Service 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.

  • Page 15: Details Screen

    • Auto Reset High Limit - An auto reset high limit is not used Is OFF in the standard configuration of the SYNC boiler. If OFF is shown then a wiring problem exists. • Run Time Contacts - Is ON when the burner is energized.
  • Page 16 Control Module 1. For proper operation of the SYNC boiler the system sensor must be connected. • Manual Shutdown - The boiler has been shutdown with the ON/OFF button on the Status Screen. Time - The time is displayed in the upper right-hand corner of the display.

  • Page 17: Main Screen

    24 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 13 - 14 for more information regarding this screen.
  • Page 18 Save button - Pressing this button will save all changes made to the control parameters. Status button - Pressing this button displays the Status Screen. This screen shows the current status of the SYNC boiler. Reference pages 13 - 14 for more information regarding this screen.
  • Page 19 Demand Configuration 6: Cascade Modbus BMS Voltage based - a 0 - 10V dc signal is provided to the boiler to control either set point or modulation. An equivalent 0 - 10V dc signal is provided by writing to the holding registers on the Modbus communication board.
  • Page 20 Service Mode will override all other heat demands, however, all safeties will remain intact. Maximum service time sets the length of time the boiler will stay in Service Mode if no buttons are pressed before reverting back to its original state. This parameter can only be changed by the installer.
  • Page 21 If the temperature drops below the temperature parameter the control will abort anti-cycling and allow the boiler to fire. This parameter can only be changed by the installer. The temperature range of this parameter is 0° to 86°F. The default value is 10°F.
  • Page 22 As the outdoor air temperature drops the water temperature set point increases. This feature allows the boiler to be more efficient in periods of mild weather. The Outdoor Reset Screen allows access to eight (8) parameters.
  • Page 23 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 For these features to work correctly, the clock must be set when the boiler is first installed or any time the boiler has been powered off for more than 30 days. To set the clock, press the SELECT button in the upper right- hand corner of the display.
  • Page 25 • Maximum Outlet Temperature - Sets the set point that individual boilers will attempt to achieve in a cascade. When a boiler is commanded to fire by the Leader, it will attempt to achieve this temperature at its outlet. The Leader...
  • Page 26 The Pumps Screen allows access to four (4) parameters. Those parameters are as follows: • Boiler Pump Delay - Sets the length of time the boiler pumps will run after a system heat call has been satisfied. This parameter can only be changed by the installer. The time range for this parameter is 0 minutes to 40 minutes.
  • Page 27 Service (continued) 0 - 10Vdc BMS Parameters Screen: 0-10Vdc Operation When the Demand Configuration parameter (see page 19) is set to either Cascade BMS Thermostat Based, Cascade BMS Voltage Based, Cascade Modbus BMS Thermostat Based, or Cascade Modbus BMS Voltage Based; a 0 - 10Vdc signal can be supplied to the terminal strip connection or through Modbus communications to control a single unit or a multiple unit cascade.
  • Page 28 Service • BMS Modulation at Minimum Voltage - Determines the modulation rate of the unit or cascade when the BMS input voltage is at or below the setting of the BMS Voltage at Minimum Modulation parameter. This parameter is only active when the BMS Type is set to modulation rate. This parameter can only be changed by the installer.

  • Page 29: Cascade Screen

    “HW” when that boiler is providing heat for a Hot Water Generation call. On Timer and Off Timer - The ON and OFF timers are used to force each boiler in the cascade to have a minimum on and off time to prevent short cycling.
  • Page 30 Boiler Enable - This displays the enable status that has been transmitted to the boiler by the Building Automation System. Boiler State - This displays the state code of the boiler. Please reference the SYNC Modbus Instruction Manual for a full definition of each code.
  • Page 31 Status button - Pressing this button displays the Status Screen. this screen shows the current status of the SYNC boiler. Reference page 13 for more information regarding this screen. Main button - Pressing this button displays the Main Screen.
  • Page 32 Status button - Pressing this button displays the Status Screen. this screen shows the current status of the SYNC boiler. Reference page 13 for more information regarding this screen. Main button - Pressing this button displays the Main Screen.
  • Page 33 Status button - Pressing this button displays the Status Screen. this screen shows the current status of the SYNC boiler. Reference page 13 for more information regarding this screen. Main button - Pressing this button displays the Main Screen.

  • Page 34: History Screen

    Status button - Pressing this button displays the Status Screen. this screen shows the current status of the SYNC boiler. Reference page 13 for more information regarding this screen. Main button - Pressing this button displays the Main Screen.
  • Page 35 Status button - Pressing this button displays the Status Screen. this screen shows the current status of the SYNC boiler. Reference page 13 for more information regarding this screen. Main button - Pressing this button displays the Main Screen.

  • Page 36: Maintenance

    • Check condensate drain system • Check automatic vents • Test low water cutoff • Reset button (low water cutoff) • Check boiler piping (gas and water) for leaks • Operate relief valve • Shut boiler down (unless boiler used for hot water generation)

  • Page 37: Address Reported Problems

    The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance WARNING and care of the boiler designated in Table 2A 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.

  • Page 38: Check Expansion Tank

    2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 psi (82.7 kPa)). 3. Watch the system pressure as the boiler heats up (during testing) to ensure pressure does not rise too high.

  • Page 39: Check Burner Flame

    4. Replace ground wires if ground continuity is not satisfactory. Check all boiler wiring 1. Inspect all boiler wiring, making sure wires are in good condition and securely attached. Check control settings 1. Go to the Setup Screen and check all settings. See Section 1 of this manual.

  • Page 40: Check Flame Signal

    • Follow the “To Turn Off Gas to Appliance” instructions for the boiler in the SYNC Installation and Operation Manual. • Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.
  • Page 41 Delta T ( is maintained. 6. When the unit stabilizes, begin to slowly shut off the isolation valve on the outlet piping of the boiler (see FIG. 2-4). This will begin to restrict the flow and simulate a low flow condition.

  • Page 42: Troubleshooting

    Troubleshooting Alarm Screen: If a fault occurs which requires a Manual Reset, the unit will go into a lockout condition and the Alarm Screen will be activated. The screen will switch between a black or red background every 5 seconds with the text “Alarm Unit Needs Servicing”...

  • Page 43: Before Troubleshooting

    PUMPS F2 - 3.15 AMP FUSE 24V SUPPLY 5. The boiler is shipped with six (6) spare fuses in a plastic bag located under the low water cutoff on the control module. 6. If necessary, replace open fuse (F3 is 1.25 amps, F2 and F4 are 3.15 amps, and F5 is 5 amps).

  • Page 44: Table 3A - Troubleshooting Chart - No Display

    Weather Shutdown (WWSD) set point for main control board. - Unit locked out on fault. - Ramp delay active. Unit Does - Boiler controlled by BMS. Not Modulate Above 50% - Flue sensor open. CAUSE • Check external line switch, fuse, or breaker.

  • Page 45: Checking Temperature Sensors

    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

    • Refer to Section 6 - Hydronic Piping of the SYNC minimum flow rates. Verify that the boiler is piped in a primary/secondary fashion and that the boiler and system pump are running on a call for heat.

  • Page 47: Table 3F - Troubleshooting Chart - Fault Messages

    Troubleshooting Table 3F Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION Flow Switch/ LWCO Either the low water cutoff or the optional (will require a manual flow switch is not making. reset once condition has been corrected. Press the RESET button on the display to reset.)

  • Page 48: Corrective Action

    Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION Burner Did Not Light (cont’d) The unit has failed to prove main burner (will require a manual ignition after one attempt. It will require a reset once the condition manual reset before attempting to fire again.
  • Page 49 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION Flame Lost While Running (cont’d) The unit was running and lost the flame (will require a signal. This condition occurred twice .
  • Page 50 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION Automatic Reset High Limit / HEX- Temp SW Either the auto-reset high limit (optional), (will require a manual or the O-temp heat exchanger switch as reset once the condition opened.
  • Page 51 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION Blower RPM’s Too High (will require a manual The actual fan rpm is 30% higher than what reset once the condition is being called for.
  • Page 52 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION Air pressure switch contacts are open. Air Flow Too (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.)
  • Page 53 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION The main control board has detected an Internal Fault internal fault. Writing to The main control board has detected an Memos internal fault.

  • Page 54: Combustion Analysis Procedure

    Troubleshooting Combustion Analysis Procedure 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.

  • Page 55: Gas Valve Adjustment Procedure

    Troubleshooting Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary, use the following procedures: (Note: The procedures below are model specific.) Under normal operating conditions this CAUTION valve should not need adjusting. Model 1.0 Locate the throttle adjustment screw on top of the gas valve, 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,...

This manual is also suitable for:

Sync 1.0Sync 1.3Sync 1.5

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