SYNC 1.0 Installation & Operation Manual

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

SYNC-I-O Rev U_2000017704_100161722

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.

Table of Contents

Need help?

Do you have a question about the 1.0 and is the answer not in the manual?

Questions and answers

Summary of Contents for SYNC 1.0

Page 1 SYNC-I-O Rev U_2000017704_100161722 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.
Page 2: Table Of 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. DETERMINE BOILER LOCATION Chilled Water System ............
Page 3: Please Read Before Proceeding
Installer – Read all instructions, including The California Safe Drinking Water and WARNING WARNING this manual and the SYNC Service Toxic Enforcement Act requires the Manual, before installing. Perform steps Governor of California to publish a list of in the order given.
Page 4: The Sync - How It Works
Device used to monitor the outlet water temperature. If the The air pressure switches detect blocked flue/vent conditions. temperature exceeds its setting, it will break the control 4. Air shrouds (1.0 Model only) circuit, shutting the boiler down. The air shrouds control air and gas flow into the burners.
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)
Page 6: Ratings
3,000 FT. TO 12,000 FT. Installation and Operation Manual. 4. Standard SYNC boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.
Page 7: Determine Boiler Location
The ventilating air openings shown in FIG.’s 1-1 and 1-2 are 4. The SYNC must be installed so that gas control system required for this arrangement. Failure to components are protected from dripping or spraying follow this warning could result in fire, water or rain during operation or service.
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.
Page 9: Provide Air Openings To Room
SYNC. Install air inlet piping for the SYNC as described in this manual. Do not terminate vent/air in locations that can allow Do not install the boiler in an attic.
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
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).
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
(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 systems of different types or manufacturers. This product has been approved for use with polypropylene vent with the manufacturers listed in Table 2D.
Page 21: Min./Max. Combustion Air & Vent Piping Lengths
UL-1738 approved system for the United States and a ULC-S636 approved system for Canada. The SYNC uses model specific combustion air intake and vent Installation of a stainless steel vent system piping sizes as detailed in Tables 2A and 2B.
Page 22: Sidewall Direct Venting
Model Kit Number Vent Size the limits given in the General Venting Section on page 16 of this manual. 1.0 - 1.5 KIT30047 6 inch vent You must consider the surroundings when terminating If using the alternate sidewall termination: the vent and air: Position the vent termination where vapors will 3.
Page 23 Supplied Fittings 12" (305 MM) MIN Table 3B Stainless Steel Sidewall Vent Kits Model Kit Number Vent Size 12” (305 MM) KIT30028 1.0 - 1.5 6 inch vent (Stainless Steel) KIT30029 1.3 - 1.5 7 inch vent BIRD (Stainless Steel)
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
CSA B149.1 Installation Code. pipe 3. The air inlet of a SYNC is part of a direct vent connection. Insert a galvanized metal thimble in the vent pipe It is not classified as a forced air intake with regard to hole (when required by local codes).
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
Figure 4-4 Alternate Vertical Terminations with Multiple Boilers 3. The air inlet of a SYNC boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.
Page 28: Hydronic Piping
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...
Page 29: Circulator Sizing
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...
Page 30 Hydronic piping Hot Water Generator pump sizing The SYNC has two (2) heat exchangers that require two (2) individual pumps for proper installation in the boiler loop and an additional two (2) pumps for the Hot Water Generator loop. Hot Water Pump Head Loss = Ft. of Head for Heat Exchanger 1 (at required flow) + Ft. of Head for the Hot Water Generator...
Page 31: Near Boiler Piping Components
Installation & Operation Manual Hydronic piping (continued) Figure 5-4 Pressure Drop vs. Flow Pressure Drop vs Flow SB1500 SB1300 SB1000 Flow Rate (GPM) - Single Heat Exchanger Only Table 5A Sizing Information for Temperature Rise Applications_20°F, 25°F, 30°F and 35°F TEMPERATURE RISE APPLICATIONS 20°F 25°F...
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.
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)
Page 34: Gas Connections Connecting Gas Supply Piping
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
Failure to (lockup) or with boiler on. support the boiler gas connection pipe • Minimum 5 inches w.c. (1.25 kPa) for 1.0 models with gas to prevent it from turning could damage flowing (verify during boiler startup). gas line components.
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
15. Turn the power switch to the “ON” position. If an in-line regulator is used, it must be a minimum of 10 feet (3 m) from the SYNC boiler. It is very important 16. Adjust the temperature set point on the control panel of...
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
2. A flow switch may be used to guarantee flow through the boiler before allowing it to fire. When used, the SYNC 3. Thermostat anticipator (if applicable): boiler requires a flow switch to be installed on each inlet.
Page 40: Wiring Of The Cascade
0 - 10 VDC input. Reference on the programmed reset curve parameters. If the outdoor air the SYNC Service Manual for more details. sensor is not connected, the Leader control will maintain the fixed water temperature set point that is programmed into the control.
Page 41 Installation & Operation Manual Field wiring (continued) Figure 7-3 Low Voltage Field Wiring Connections MOD BUS CASCADE...
Page 42: Condensate Disposal
Condensate horizontal runs, a second line vent may from the SYNC will be slightly acidic (typically with a pH be required and tubing size may need to from 3 to 5). Install a neutralizing filter if required by increase to 1 inch (25 mm).
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
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. Read this manual, page 46 for proper steps to start boiler.
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 See the SYNC Service Manual for a detailed Note: Heat Exchanger 1 is the top heat exchanger; please explanation of this procedure.
Page 48 SELECT button. in the control must be changed. See the SYNC Service Manual for a detailed explanation of this procedure. If there 2. The first time the cascade setup parameters are accessed, is an active space heating call for heat, then the boiler pumps you will be required to enter the service password.
Page 49: Operating Information
Temperature control Modulation The SYNC is capable of modulating its firing rate from a minimum of 10% to a maximum of 100%. The firing rate is dictated by the call for heat (i.e., space heating or hot water generation), the heating load, and various other temperature limitations.
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.
Page 51: Cascade
Target temperature is fixed when the outdoor calculated based on the programmed reset curve parameters. sensor is not installed. See the SYNC Service Manual to program the reset curve. If outdoor air reset is not desired, do not connect the outdoor air •...
Page 52 Cascade (see to provide heat for a HW call. Select a boiler to be designated the SYNC Service Manual for an explanation of the offset and as the HW boiler. Connect the HW thermostat or sensor to differential).
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
LCD display will be the Status a 0-10 VDC BMS control. Screen. This screen displays the current status of the SYNC • Service Set Point Met - While in Service Mode, the boiler. The following items can be viewed or interacted with...
Page 55 Reference the Inlet Water Temperature - This is a calculated temperature Details Screen section in the SYNC Service Manual for more based on the inlet temperature readings from the two (2) heat information regarding this screen.
Page 56: Main Screen
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
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 • Check boiler area •...
Page 58: Address Reported Problems
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 Visually inspect the entire flue gas venting system and air YEARS, by a licensed plumbing contractor piping for blockage, deterioration or leakage.
Page 60: Check Burner Flame
Service Manual. Adjust settings if necessary. See Section 1 of the SYNC Service Manual for 3. See Section 3 - Troubleshooting in the SYNC Service Manual adjustment procedures. for other procedures to deal with low flame signal. 2. Check settings of external limit controls (if any) and Review with owner adjust if necessary.
Page 61: Cleaning Boiler Heat Exchanger
• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 9 - Startup. SB 1.0 - 1.5 KIT30064 MSC20085 1/4" x 12" Drill Extension • Do not drain the boiler unless it will be exposed to freezing temperatures.
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...
Page 65: Wiring Diagram
Installation & Operation Manual Diagrams (continued) Figure 12-3 Wiring Diagram...
Page 66 Notes...
Page 67 Notes...
Page 68: Revision Notes
Revision E (ECO #C04062) reflects changes to the terminology in all logos on page 6. SYNC manuals and labels from module to heat exchanger (exception: Revision N (ECO C10594) reflects the update of Wiring and control module), along with changing out “dirt separator” for “Y-strainer Ladder diagrams on pages 64 and 65.

This manual is also suitable for:

1.3 1.5