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SYNC-I-O Rev I
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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Table of Contents
Related Manuals for Lochinvar 1.3
Summary of Contents for Lochinvar 1.3
- Page 1 SYNC-I-O Rev I 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.
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Page 2: Table Of Contents
Flooring and Foundation ... 9 Vent and Air Piping ... 9 Prevent Combustion Air Contamination ... 9 Using an Existing Vent System to Install a New Boiler ... 10 Corrosive Contaminants and Sources ... 10 Removing a Boiler from Existing Common Vent ... 11 Remove Boiler from Wood Pallet ... -
Page 3: Please Read Before Proceeding
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. Any appliance that has been under water must be replaced. -
Page 4: The Sync - How It Works
Conduit connection points for the low voltage connection board. 32. Low water cutoff device (LWCO) Device used to ensure adequate water is supplied to the boiler and in the event of inadequate water levels, will ensure the boiler will shut down. 33. Power switch Turns 120 VAC ON/OFF to the boiler. -
Page 5: The Sync -- How It Works
The SYNC - How it works... Models 1.0 - 1.3 - 1.5 Front View 1.0 Model Only Left Side (inside unit) (continued) Rear View Right Side (inside unit) Installation & Operation Manual... -
Page 6: Ratings
5. High altitude SYNC boilers are equipped to operate from 3,000 to 12,000 feet only with no field adjustments. The boiler will de-rate by 2% for each 1,000 feet above 3,000 feet. High altitude models are manufactured with a different control module for altitude operation, but the operation given in this manual remains the same as the standard boilers. -
Page 7: Determine Boiler Location
Closet and alcove installations A closet is any room the boiler is installed in which is less than 778 cubic feet for SB1000 models, 847 cubic feet for SB1300 models, and 914 cubic feet for SB1500 models. - Page 8 Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances 1/4” (6 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES 1” (25 MM) MINIMUM CLEARANCE AROUND VENT PIPES 24" (610 MM) RECOMMENDED SERVICE CLEARANCES: Front 30" (762 mm) 24" (610 mm) Left Side - 24"...
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Page 9: Provide Air Openings To Room
Do not attempt to install the SYNC using any other means. Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual. -
Page 10: Using An Existing Vent System To Install A New Boiler
• Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 11. With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used;... -
Page 11: Removing A Boiler From Existing Common Vent
At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. -
Page 12: Combustion And Ventilation Air Requirements
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... - Page 13 Determine boiler location Figure 1-7_Combustion Air from Outside - Single Opening If 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 free area of one square inch per 3000 Btu/hr (7 cm opening must be located within 12"...
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Page 14: General Venting
Installation & Operation Manual General venting Direct venting options - Sidewall Vent Stainless Steel PVC/CPVC Two Pipe Two Pipe See Figure 3-1A See Figure 3-2 Sidewall Vent Optional Room Air PVC/CPVC Stainless Steel Room Air Room Air See Figure 4-5 See Figure 4-5... -
Page 15: Direct Venting Options - Vert. Vent Opt. Rm Air
Installation & Operation Manual General venting (continued) Direct venting options - Vertical Vent PVC/CPVC Stainless Steel Two Pipe Two Pipe See Figure 4-1 See Figure 4-2 Vertical Vent Optional Room Air PVC/CPVC Stainless Steel Room Air Room Air See Figure 4-5 See Figure 4-5... -
Page 16: Direct Venting Options - Vert. Vent, Horz. Air
Installation & Operation Manual General venting Direct venting options - Vertical Vent, Sidewall Air PVC/CPVC Vertical Vent, Sidewall Air Stainless Steel Vertical Vent, Sidewall Air... -
Page 17: Install Vent And Combustion Air Piping
All PVC vent pipes must be glued, NOTICE properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate). This appliance requires a special venting WARNING system. -
Page 18: Pvc/Cpvc Air Intake/Vent Connections
A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate. Figure 2-2 Near Boiler PVC/CPVC Venting VENT PVC/CPVC ADAPTER FACTORY INSTALLED Air inlet pipe materials: The air inlet pipe(s) must be sealed. -
Page 19: Requirements For Installation In Canada
NOTICE that are approved for the materials which are joined together. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends. -
Page 20: Stainless Steel Vent And Air Piping
Stainless steel vent and air piping This product has been approved for use with stainless steel FasNseal vent systems manufactured by Dura-vent. Lochinvar offers a matching stainless steel sidewall vent termination kit, see Table 3A on page 22. Use only the materials, vent systems, and WARNING terminations listed in Table 2B. -
Page 21: Min./Max. Combustion Air & Vent Piping Lengths
Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion). You may use any of the vent/air piping methods covered in this manual. -
Page 22: Sidewall Direct Venting Vent/Air Termination - Sidewall
FIG.’s 3-1B and 3-1C. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown. Figure 3-1B Alternate Sidewall Termination of Air and Vent w/Field Supplied Fittings... - Page 23 Kit Number KIT30028 1.0 - 1.5 (Stainless Steel) KIT30029 1.3 - 1.5 (Stainless Steel) Maintain clearances as shown in FIG.’s 3-1A thru 3-4B, pages 22 and 24. Also maintain the following: Vent must terminate: • At least 6 feet (1.8 m) from adjacent walls.
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Page 24: Prepare Wall Penetrations
Sidewall direct venting Figure 3-3B Alternate Clearance to Forced Air Inlets w/ Field Supplied Fittings 7’ (2.1 M) MIN ABOVE ANY PUBLIC WALKWAY Prepare wall penetrations Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes. Air pipe penetration: Cut a hole for the air pipe. -
Page 25: Termination And Fittings
3. The air inlet of a SYNC is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents. Figure 3-5A Multiple Vent Terminations (must also comply with Figure 3-1A) 12"... -
Page 26: Vertical Direct Venting Vent/Air Termination - Vertical
Vertical direct venting Vent/air termination – vertical Follow instructions below when determining WARNING vent location to avoid possibility of severe personal injury, death or substantial property damage. Do not connect any other appliance to the WARNING vent pipe or multiple boilers to a common vent pipe. -
Page 27: Multiple Vent/Air Terminations
For Canadian installations, provide clearances required by CSA B149.1 Installation Code. 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
It is important to note that the boiler has a pressure drop which must be figured in when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. -
Page 29: Circulator Sizing
Figure 5-1A Near Boiler Piping w/Y-Strainer ISOLATION VALVE (TYPICAL) Y-STRAINER (RECOMMENDED) (TYPICAL) HEAT EXCHANGER 1 BOILER PUMP Figure 5-1B Near Boiler Piping w/Low Loss Header DRAIN VALVE ISOLATION VALVE (TYPICAL) HEAT EXCHANGER 1 BOILER PUMP HEAT EXCHANGER 2 BOILER PUMP... - 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
Factory supplied. The pressure relief valve is sized to ASME specifications. 10. System temperature sensor: Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. - Page 32 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. System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in NOTICE operation to prevent short cycling and high limit issues.
- Page 33 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. System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in NOTICE operation to prevent short cycling and high limit issues.
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Page 34: Gas Connections Connecting Gas Supply Piping
Gas connections Connecting gas supply piping 1. Refer to FIG. 6-1 to pipe gas to the boiler. Install ground joint union for servicing, when required. In Canada – When using manual main shutoff valves, it must be identified by the installer. -
Page 35: Natural Gas
• Minimum 5 inches w.c. (1.25 kPa) for 1.0 models with gas flowing (verify during boiler startup). • Minimum 4 inches w.c. (.99 kPa) for 1.3 - 1.5 models with gas flowing (verify during boiler startup). 2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w.c. -
Page 36: Check Inlet Gas Supply
NOTICE acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fire at full rate. Consult with local codes for proper installation or service procedures. DO NOT adjust or attempt to measure gas WARNING valve outlet pressure. -
Page 37: Gas Pressure
(static) mode and while in operating (dynamic) mode. 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 that the gas line is properly purged by the gas supplier or utility company. -
Page 38: Field Wiring
Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. NOTICE If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent. Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 –... -
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 boiler requires a flow switch to be installed on each inlet. 3. Remove the jumper wires from the terminals on the connection board and connect these terminals to the normally open contacts on the flow switches (FIG. -
Page 40: Wiring Of The Cascade
Cascade, daisy chain the wiring from the Sequencing terminals on the second boiler to the Sequencing terminals on the third boiler, then from the third to the forth, and so on. The connections between boilers can be made in any order, regardless of the addresses of the boilers. - 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 Condensate Drain
Condensate drain 1. This boiler is a high efficiency appliance that produces condensate. 2. The rear of the boiler has a 1/2 inch (12.7 mm) PVC union for connection of a 1/2 inch (12.7 mm) PVC pipe (FIG. 8-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter. -
Page 43: Startup
200 ppm. 2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower. 3. Do not use the boiler to directly heat swimming pool or spa water. Test/replace freeze protection fluid 1. -
Page 44: Check For Gas Leaks
(This is a common problem when using 3-wire zone valves.) 2" PVC CAP WITH BLOCKED DRAIN SWITCH 5. Once the external boiler enable wiring is checked and RETAINING corrected if necessary, reconnect the external thermostat SCREW circuit wires to the connection board. -
Page 45: Start The Boiler
SMART TOUCH control module operation. Read this manual, page 46 for proper steps to start boiler. Verify the boiler and system are full of water and all system components are correctly set for operation. Verify the preparation procedures of Section 9, pages 43 and 44 have been completed. -
Page 46: For Your Safety Read Before Operating
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. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. -
Page 47: Set Space Heating Operation
HW (Hot Water) tank, it also turns on the boiler pump. After the space heating call for heat ends, the system pump continues to run for a short period of time. If the boiler pump was running, it continues to run for a short period of time as well. -
Page 48: Startup
See the SYNC Service Manual for a detailed explanation of this procedure. If there is an active space heating call for heat, then the boiler pumps will be turned on and the HW pumps will be turned off. -
Page 49: Operating Information
As long as the space heating call for heat is on, the system pump will remain on. If a HW call for heat is on, the boiler pumps will wait to turn on until just before the HW pumps turn off. After the space heating call for heat ends, both pumps will run for an additional period of time. - Page 50 55°F (31°C) and the minimum off time has expired. Freeze protection DO NOT install the boiler in a room likely to freeze. The following integral feature of the SMART TOUCH control module provides some protection for the boiler only -- not for the system.
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Page 51: Cascade
Leader control and all others would be designated as Member controls. Once the Leader boiler receives a call for heat from the Enable input or 0 - 10 VDC input, the control will determine what the set point will be. -
Page 52: Cascade
100% of its firing rate, the Leader will calculate at what point the second boiler could fire at 10% of its firing rate. At this point, the Leader will fire the second boiler on the Cascade. For a new startup, this would be the first Member boiler. -
Page 53: Sequence Of Operation
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. 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 54: Status Screen
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 Operating information 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.
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Page 56: Main Screen
SYNC Servie Manual 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 54 - 55 for more information regarding this screen. -
Page 57: Maintenance
• Check condensate drain system • Check automatic air 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... -
Page 58: 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 11A 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 59: 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 60: Check Burner Flame
1. Inspect flame through observation window. 2. If the flame is unsatisfactory at either high fire or low fire, turn off boiler and allow boiler to cool down. Remove the burners and clean them thoroughly using a vacuum cleaner or compressed air. - Page 61 • Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain. 2. Allow time for the boiler to cool to room temperature if it has been firing. 3. Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside.
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Page 62: Handling Ceramic Fiber Materials
Apply enough water to the combustion chamber lining to prevent airborne dust. Remove the combustion chamber lining from the boiler and place it in a plastic bag for disposal. Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly. -
Page 63: Diagrams
Diagrams Figure 12-1 Ladder Diagram_Part 1 LOUVER RELAY 1 FLAP VALVE INLET SENSOR OUTLET SENSOR FLUE SENSOR GAS VALVE BLOWER SPARK CAUTION HIGH VOLTAGE SPARK LEAD CONNECTION BOARD SHIELD CASCADE RS485 SHIELD TANK SENSOR OUTDOOR SENSOR SYSTEM SENSOR EXTERNAL 10VDC CONTROL SHIELD MOD BUS... -
Page 64: Ladder Diagrams
Installation & Operation Manual Diagrams Figure 12-2 Ladder Diagram_Part 2... -
Page 65: Wiring Diagram
Installation & Operation Manual LOW VOLTAGE 120 VAC HIGH VOLTAGE BOX DEPICTS OPTIONAL ITEMS JUNCTION LOUVER CONTACTS RELAY LOUVER BOARD BOILER 2 BOILER 1 SYSTEM PUMP HW PUMP RELAY ON/OFF SWITCH 120V SUPPLY BLOWER LOUVER LOUVER RELAY 1 RELAY 1... - 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.