Lochinvar SYNC 1.0 Installation & Operation Manual
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- User's information manual (16 pages) ,
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- Service manual (56 pages)
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SYNC-I-O Rev S
Installation & Operation Manual
Models: 1.0 - 1.3 - 1.5
This manual must only be used by
WARNING
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.
Save this manual for future reference.
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Summary of Contents for Lochinvar SYNC 1.0
- Page 1 SYNC-I-O Rev S Installation & Operation Manual Models: 1.0 - 1.3 - 1.5 This manual must only be used by WARNING 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.
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Page 2: Table Of Contents
Contents HAZARD DEFINITIONS ............ 2 Room Air ................27 PLEASE READ BEFORE PROCEEDING ......3 5. HYDRONIC PIPING THE SYNC -- HOW IT WORKS........4-5 System Water Piping Methods ......... 28 RATINGS ................6 Low Water Cutoff Device ..........28 1. -
Page 3: Please Read Before Proceeding
Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including WARNING DO NOT install units in rooms or WARNING this manual and the SYNC Service environments that contain corrosive Manual, before installing. Perform steps contaminants (see Table 1A on page 10). in the order given. -
Page 4: The Sync - How It Works
Installation & Operation Manual The SYNC - How it works... 23. Heat exchanger access covers Access cover - front Allows access to the combustion side of the heat Provides access to the gas train and the heat exchanger. exchanger coils. Air intake adapter 24. - Page 5 Installation & Operation Manual The SYNC - How it works... (continued) Models 1.0 - 1.3 - 1.5 Front View Rear View 1.0 Model Only IMG00971 IMG00970 Left Side (inside unit) Right Side (inside unit)
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Page 6: Ratings
Installation & Operation Manual Ratings SYNC Other Specifications AHRI Rating Input Vent Appliance Model Number Gross Size Water Outlet Inlet AHRI Output Size Content Water Water Connections Ratings Note: Change “N” to Gallons Water, (Note 3) (Note 4) “L” for L.P. gas models. (Note 1) (Note 2) 3"... -
Page 7: Determine Boiler Location
Installation & Operation Manual Determine boiler location Installation must comply with: This appliance is certified as an indoor WARNING appliance. Do not install the appliance • Local, state, provincial, and national codes, laws, regulations, and ordinances. outdoors or locate where the appliance will be exposed to freezing temperatures or to •... - Page 8 Installation & Operation Manual Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances 1/4” (6 MM) MINIMUM CLEARANCE For closet installations, CPVC, WARNING AROUND HOT WATER PIPES polypropylene or stainless steel 1” (25 MM) MINIMUM CLEARANCE AROUND VENT PIPES vent material MUST BE used in a closet structure due to elevated temperatures.
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Page 9: Provide Air Openings To Room
Installation & Operation Manual Determine boiler location (continued) Provide air openings to room: Vent and air piping The SYNC requires a special vent system, designed for The SYNC alone in boiler room pressurized venting. 1. No air ventilation openings into the boiler room are The boiler is to be used for either direct vent installation or needed when clearances around the SYNC are at least for installation using indoor combustion air. -
Page 10: Using An Existing Vent System To Install A New Boiler
Installation & Operation Manual Determine boiler location When using an existing vent system to Table 1A Corrosive Contaminants and Sources install a new boiler: Products to avoid: Failure to follow all instructions can result WARNING in flue gas spillage and carbon monoxide Spray cans containing chloro/fluorocarbons emissions, causing severe personal injury Permanent wave solutions... -
Page 11: Removing A Boiler From Existing Common Vent
Installation & Operation Manual Determine boiler location (continued) When removing a boiler from existing Remove boiler from wood pallet common vent system: 1. After removing the outer shipping carton from the boiler, Do not install the SYNC into a common remove the parts package (packaged parts inside the jacket DANGER vent with any other appliance. -
Page 12: Combustion And Ventilation Air Requirements
Installation & Operation Manual Determine boiler location Combustion ventilation requirements for appliances drawing air from the 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. - Page 13 Installation & Operation Manual Determine boiler location (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).
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Page 14: General Venting
Installation & Operation Manual General venting Direct venting options - Sidewall Vent Figure 2-1 Two Pipe Sidewall Termination - See page 22 for more details Direct venting options - Vertical Vent Figure 2- 2 Two Pipe Vertical Termination - Figure 2-3 Vertical Vent, Sidewall Air See page 26 for more details... -
Page 15: Direct Venting Options - Vert. Vent Opt. Rm Air
Installation & Operation Manual General venting (continued) Install vent and combustion air piping The SYNC boiler must be vented and The SYNC boiler vent and air piping can be installed through DANGER supplied with combustion and ventilation the roof or through a sidewall. Follow the procedures in this air as described in this section. -
Page 16: Direct Venting Options - Vert. Vent, Horz. Air
Installation & Operation Manual General venting Sizing Requirements for installation in Canada The SYNC boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 2A Installations must be made with a vent pipe system below. certified to ULC-S636. -
Page 17: Install Vent And Combustion Air Piping
Installation & Operation Manual General venting (continued) Materials Air inlet pipe materials: The PVC, CPVC, or ABS air inlet pipe should be cleaned and The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. -
Page 18: Pvc/Cpvc Air Intake/Vent Connections
Installation & Operation Manual General venting Optional room air Applications utilizing the SYNC boiler may be installed with Table 2B Room Air Minimum / Maximum Allowable Air / a single pipe carrying the flue products to the outside while Vent Lengths using combustion air from the equipment room. -
Page 19: Requirements For Installation In Canada
Installation & Operation Manual General venting (continued) PVC/CPVC Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent This product has been approved for use with the PVC/CPVC piping. -
Page 20: Stainless Steel Vent And Air Piping
Installation & Operation Manual General venting Use only the adapters and vent system listed Polypropylene WARNING in Tables 2E and 2F. DO NOT mix vent This product has been approved for use with polypropylene systems of different types or manufacturers. vent with the manufacturers listed in Table 2D. -
Page 21: Min./Max. Combustion Air & Vent Piping Lengths
Installation & Operation Manual General venting (continued) Stainless steel vent Installation of a stainless steel vent system NOTICE 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. -
Page 22: Sidewall Direct Venting
Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Figure 3-1A PVC/CPVC/Centrotherm Sidewall Termination of Air and Vent Follow instructions below when WARNING TO BOILER Note: Available in 6" determining vent location to avoid INTAKE AIR diameter only. CONNECTION possibility of severe personal injury, death, or substantial property damage. - Page 23 Installation & Operation Manual Sidewall direct venting (continued) Vent/air termination – sidewall Figure 3-2A Clearance to Gravity Air Inlets Figure 3-1C Alternate Stainless Steel Sidewall Termination w/Field Supplied Fittings PVC/CPVC or ABS is acceptable air inlet pipe material. NOTICE 12" MIN.
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Page 24: Prepare Wall Penetrations
Installation & Operation Manual Sidewall direct venting 8. PVC/CPVC terminations are designed to accommodate any Figure 3-3B Alternate Clearance to Forced Air Inlets w/ wall thickness of standard constructions per the directions Field Supplied Fittings found in this manual. IF LESS 9. -
Page 25: Termination And Fittings
Installation & Operation Manual Sidewall direct venting (continued) Multiple vent/air terminations Prepare wall penetrations (Alternate Field Supplied Options) 1. When terminating multiple SYNC boilers terminate Air pipe penetration (see FIG. 3-4B): each vent/air connection as described in this manual Cut a hole for the air pipe. Size the air pipe hole as (FIG. -
Page 26: Vertical Direct Venting
Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Figure 4-1 PVC/CPVC/Polypropylene Vertical Termination of Air and Vent Follow instructions below when ALTERNATE INTAKE LOCATIONS: WARNING INTAKE PIPES MAY BE LOCATED determining vent location to avoid ANYWHERE WITHIN 24" (610 MM) possibility of severe personal injury, death OF VENT PIPE or substantial property damage. -
Page 27: Multiple Vent/Air Terminations
Installation & Operation Manual Vertical direct venting (continued) Multiple vent/air terminations Figure 4-3 Vertical Terminations with Multiple Boilers 1. When terminating multiple SYNC boilers, terminate each vent/air connection as described in this manual 12" (305 MM) MINIMUM (FIG. 4-3). VERTICALLY FROM VENT OUTLET TO ANY AIR INLET VENT Terminate all vent pipes at the same height... -
Page 28: Hydronic Piping
Installation & Operation Manual Hydronic piping System water piping methods General piping information The SYNC is designed to function in a closed loop pressurized Basic steps are listed below along with illustrations on the system not less than 12 psi (83 kPa). A temperature and following pages (FIG.’s 5-5 and 5-6), which will guide you pressure gauge is included to monitor system pressure and through the installation of the SYNC (reference FIG.s 5-1A and... -
Page 29: Circulator Sizing
Installation & Operation Manual 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 connections Figure 5-1A Near Boiler Piping w/Y-Strainer Figure 5-1B Near Boiler Piping w/Low Loss Header... - Page 30 A T of 30° requires a flow through each heat exchanger of 51 GPM. The heat exchanger head loss is 18 ft. 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.
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Page 31: Near Boiler Piping Components
10. System temperature sensor: performance. Lochinvar supplies a system temperature sensor. 2. Boiler circulating pump: The sensor is to be installed in the heating loop Field supplied. The boiler circulating pump MUST be... - Page 32 Installation & Operation Manual Hydronic piping Figure 5-5 Single Boiler - Primary/Secondary Piping system supply sensor (factory NOTICE supplied) MUST BE installed for proper boiler operation. Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
- Page 33 Installation & Operation Manual Hydronic piping (continued) Figure 5-6 Multiple Boilers - Primary/Secondary Piping Number of Units Model Manifold Pipe Sizes in Inches (mm) 1000 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 8 (203) 8 (203) 1300 5 (127) 5 (127) 6 (152)
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Page 34: Gas Connections
Installation & Operation Manual Gas connections Connecting gas supply piping 3. Support piping with hangers, not by the boiler or its accessories. 1. Refer to FIG. 6-1 to pipe gas to the boiler. The gas valve and blower will not support Install ground joint union for servicing, when WARNING the weight of the piping. -
Page 35: Natural Gas
Installation & Operation Manual Gas connections (continued) Natural gas supply pressure requirements Use two wrenches when tightening gas WARNING piping at boiler (FIG. 6-2), using one 1. Pressure required at the gas valve inlet pressure port: wrench to prevent the boiler gas line •... -
Page 36: Check Inlet Gas Supply
Installation & Operation Manual Gas connections Table 6A Natural Gas Pipe Size Chart Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c. pressure drop) Pipe Length of Pipe in Straight Feet Size (Inches) 1 1/4... -
Page 37: Gas Pressure
Installation & Operation Manual Gas connections (continued) Gas Pressure Do not check for gas leaks with an open WARNING flame -- use the bubble test. Failure to The gas pressure must remain between 4 inches w.c. use the bubble test or check for gas leaks (.99 kPa) minimum (5 inches w.c. -
Page 38: Field Wiring
Installation & Operation Manual Field wiring Installation must comply with: ELECTRICAL SHOCK HAZARD – For WARNING your safety, turn off electrical power supply before making any electrical connections 1. National Electrical Code and any other national, state, to avoid possible electric shock hazard. provincial, or local codes, or regulations. -
Page 39: Low Voltage Connections
Installation & Operation Manual Field wiring (continued) Low voltage connections Water Generator (HW) thermostat 1. Route all low voltage wires through the knockouts in the rear of the boiler, as shown in FIG. 7-2. 1. Connect the HW tank thermostat to the Tank Thermostat terminals on the connection board (FIG. -
Page 40: Wiring Of The Cascade
Installation & Operation Manual Field wiring System supply sensor Wiring of the cascade 1. By installing the system supply sensor into the supply When wiring the boilers for Cascade operation, select one boiler of the primary loop, the temperature of the system as the Leader boiler. - Page 41 Installation & Operation Manual Field wiring (continued) Figure 7-3 Low Voltage Field Wiring Connections MOD BUS CASCADE...
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Page 42: Condensate Disposal
Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of 1. This boiler is a high efficiency appliance that produces other authority, PVC and CPVC pipe condensate. must comply with ASTM D1785 or D2845. Cement and primer must comply with 2. -
Page 43: Startup
Installation & Operation Manual Start-up Check/control water chemistry 4. At initial fill and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before Do not use petroleum-based cleaning or proceeding further. CAUTION sealing compounds in the boiler system. Eliminate all system leaks. -
Page 44: Check For Gas Leaks
Installation & Operation Manual Start-up Check for gas leaks Before starting the boiler, and during Propane boilers only – Your propane WARNING WARNING initial operation, smell near the floor and supplier mixes an odorant with the propane around the boiler for gas odorant or any to make its presence detectable. -
Page 45: Start The Boiler
Installation & Operation Manual Start-up (continued) Final checks before starting the boiler Check vent piping and air piping 1. Check for gastight seal at every connection, seam of air Read the SYNC Service Manual to familiarize yourself piping, and vent piping. with SMART TOUCH control module operation. -
Page 46: For Your Safety Read Before Operating
Installation & Operation Manual 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. • A. - Page 47 Installation & Operation Manual Start-up (continued) Check flame and combustion Set space heating operation (continued) 4. Navigate to the Service Mode Screen from the Status Verify space heat circulator mode Screen by pressing the MAIN button and then the SERVICE MODE button. The Space Heating Mode controls the system pump (if connected), and both boiler pumps.
- Page 48 Installation & Operation Manual Start-up If no other changes are necessary, press the BACK button Using the keypad, adjust the date and time by working to return to the Parameter List Screen. from left to right. If a digit has been entered incorrectly, press the left arrow key on the keypad to back the digit Once all the necessary adjustments have been made, up.
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Page 49: Operating Information
Installation & Operation Manual Operating information General HW priority The SMART TOUCH control module allows connection of a How the boiler operates HW thermostat to the low voltage connection board. When the HW thermostat calls for heat, the control modules activate the The SYNC uses advanced stainless steel heat exchangers HW pumps, shuts down the boiler pumps, and immediately and electronic control modules that allow fully condensing... - Page 50 Installation & Operation Manual Operating information Protection features Gradient limiting If during operation of the boiler the outlet water temperature Outlet temperature, flue temperature, and temperature is rising too quickly, the control will reduce the firing rate rise limiting to its lowest setting. The outlet temperature is monitored by the boiler outlet Outdoor air reset temperature sensor.
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Page 51: Cascade
Installation & Operation Manual Operating information (continued) Monitor external limits High limit operations Connections are provided on the connection board for When outlet temperature exceeds 200°F (93.3°C), high limit external limits such as flow switch and a louver proving action occurs. The boiler shuts down until the outlet water switch. - Page 52 Installation & Operation Manual Operating information If the water temperature at the system supply sensor is less HW operation with cascade than the set point + the turn-off offset - the off-on differential, For HW operation any boiler(s) in the Cascade can be selected then the control will initiate a call for heat on the Cascade (see to provide heat for a HW call.
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Page 53: Sequence Of Operation
Installation & Operation Manual Operating information (continued) 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. -
Page 54: Status Screen
Installation & Operation Manual Operating information 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. - Page 55 Installation & Operation Manual Operating information (continued) 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 56: Main Screen
Installation & Operation Manual Operating information 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. -
Page 57: Maintenance
Installation & Operation Manual Maintenance Maintenance and annual startup Table 11A 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, if any •... -
Page 58: Inspect Boiler Area
Installation & Operation Manual Maintenance 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 59: Check Expansion Tank
Installation & Operation Manual Maintenance (continued) 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. -
Page 60: Check Burner Flame
Installation & Operation Manual Maintenance Inspect ignition flame Check burner flame sense electrodes 1. Inspect flame through observation window. 1. Remove the ignition and flame sense electrodes 2. If the flame is unsatisfactory at either high fire or low fire, from the boiler heat exchanger access covers. - Page 61 Installation & Operation Manual Maintenance (continued) Cleaning boiler heat exchanger Table 11B Heat Exchanger Cleaning Kits For recommended materials; including brush, appropriate extension(s), refractory cover, and detailed instructions see Model Part Component Table 11B - Heat Exchanger Cleaning Kits. Number Number Number Description...
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Page 62: Handling Ceramic Fiber Materials
Installation & Operation Manual Maintenance 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 63: Diagrams
Installation & Operation Manual Diagrams Figure 12-1 Ladder Diagram_Part 1 BOX DEPICTS OPTIONAL ITEMS LOW VOLTAGE 120 VAC HIGH VOLTAGE CONTROL CONTROL MODULE 1 MODULE 2 LOUVER RELAY 1 X6-8 X5-7 X5-7 X5-7 LOUVER X5-4 RELAY 2 X5-4 FLAP AIR PRESSURE FLAP AIR PRESSURE VALVE... - Page 64 Installation & Operation Manual Diagrams Figure 12-2 Ladder Diagram_Part 2...
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Page 65: Wiring Diagram
Installation & Operation Manual Diagrams (continued) Figure 12-3 Wiring Diagram... - Page 66 Notes...
- Page 67 Notes...
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Page 68: Revision Notes
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 on page 48 along with the addition of the Flow Sensing Device section.
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