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Contents
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
HAZARD DEFINITIONS
.................................................... 2
PLEASE READ BEFORE PROCEEDING
........................ 3
THE SYNC -- HOW IT WORKS
...................................... 4-5
RATINGS
........................................................................... 6
1. DETERMINE BOILER LOCATION
Closet and Alcove Installations .......................................... 7
Provide Air Openings to Room .......................................... 9
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 ..................................... 11
Combustion and Ventilation Air Requirements ........... 12-13
2. GENERAL VENTING
Direct Venting Options - Sdwl/Horz. Vent Opt. Rm Air .... 14
Direct Venting Options - Vert. Vent Opt. Rm Air ............... 15
Direct Venting Options - Vert. Vent, Horz. Air ................. 16
Install Vent and Combustion Air Piping ........................... 17
PVC / CPVC Vent Piping Materials ............................ 17
PVC/CPVC Air Intake/Vent Connections ......................... 18
Air Inlet Pipe Materials ................................................ 18
Requirements for Installation in Canada .......................... 19
Installing Vent and Air Piping ........................................... 19
Stainless Steel Vent and Air Piping ................................. 20
Min./Max. Combustion Air & Vent Piping Lengths ........... 21
Vent and Air Piping .......................................................... 21
3. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall ................................... 22-25
Determine Location ................................................ 22-24
Prepare Wall Penetrations .......................................... 24
Termination and Fittings ............................................. 25
Multiple Vent/Air Terminations .................................... 25
4. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical .................................... 26-27
Determine Location ..................................................... 26
Prepare Roof Penetrations ......................................... 26
Termination and Fittings ........................................ 26-27
Multiple Vent/Air Terminations .................................... 27
Room Air .......................................................................... 27
5. HYDRONIC PIPING
System Water Piping Methods ......................................... 28
Low Water Cutoff Device ................................................. 28
Chilled Water System ....................................................... 28
Freeze Protection ............................................................. 28
General Piping Information .............................................. 28
Circulator Sizing ............................................................... 29
Near Boiler Piping Connections ....................................... 29
Near Boiler Piping Components .................................. 31-33
6. GAS CONNECTIONS
Connecting Gas Supply Piping ........................................ 34
Natural Gas ...................................................................... 35
Pipe Sizing for Natural Gas ........................................ 35
Natural Gas Supply Pressure Requirements ............. 35
Propane Gas .................................................................... 35
Pipe Sizing for Propane Gas ...................................... 35
Propane Supply Pressure Requirements ................... 35
Check Inlet Gas Supply .............................................. 36-37
Gas Pressure ................................................................... 37
Gas Valve Replacement .................................................. 37
7. FIELD WIRING
Line Voltage Connections ................................................ 38
Low Voltage Connections ................................................ 39
Wiring of the Cascade ...................................................... 40
8. CONDENSATE DISPOSAL
Condensate Drain ............................................................ 42
9. STARTUP
............................................................... 43-48
10. OPERATING INFORMATION
General ........................................................................ 49-51
Cascade ...................................................................... 51-52
Sequence of Operation .................................................... 53
Status Screen .............................................................. 54-55
Main Screen ..................................................................... 56
11. MAINTENANCE
Maintenance & Annual Startup .............................. 57-62
12. DIAGRAMS
Ladder Diagrams ................................................... 63-64
Wiring Diagram ........................................................... 65
Revision Notes .................................................. Back Cover
Summary of Contents for Sunc 1.0
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