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26

        

Installation & Operation Manual

4  

Vertical direct venting  

Vent/air termination – vertical 

Prepare roof penetrations

1. Air 

pipe 

penetration:

a.  Cut a hole for the air pipe.  Size the air pipe hole as 
 

close as desired to the air pipe outside diameter.

2.  Vent pipe penetration:

a.  Cut a hole for the vent pipe.  For either combustible 
 

or noncombustible construction, size the vent pipe 

 

hole with at least a 1/2 inch clearance around the 

 

vent pipe outer diameter:

 

 

•  7½ inch (178 mm) hole for 6 inch (152 mm) vent 

  

 

pipe

 

 

•  8½ inch (203 mm) hole for 7 inch (178 mm) vent 

  

 

pipe 

b.  Insert a galvanized metal thimble in the vent pipe 
 

hole (when required by local codes).

3.  Space the air and vent holes to provide the minimum 

spacing shown in FIG.’s 4-1 and 4-2.

4.  Follow all local codes for isolation of vent pipe when 

passing through floors, ceilings, and roofs.

5.  Provide flashing and sealing boots sized for the vent pipe 

and air pipe.

Termination and fittings

1.  Prepare the vent termination coupling and the air 

termination elbow (FIG.’s 4-1 and 4-2) by inserting bird 
screens.  Bird screens should be obtained locally.  

2.  The air piping must terminate in a down-turned 180° 

return bend as shown in FIG.’s 4-1 and 4-2.  Locate the 
air inlet pipe no further than 2 feet (.6 m) from the center 
of the vent pipe.  This placement avoids recirculation of 
flue products into the combustion air stream.

ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED 
ANYWHERE WITHIN 24" (610 MM) 
OF VENT PIPE

BIRD SCREEN
        (TYPICAL)

            COUPLING
(FIELD SUPPLIED)

      VENT OUTLET
        12" MINIMUM
ABOVE AIR INLET

6" (152 MM) MINIMUM
ABOVE ROOF /
SNOW LINE

VENT

COMBUSTION
        AIR

Figure 4-1  PVC/CPVC Vertical Termination of Air and 
Vent

5.  Locate terminations so they are not likely to be damaged 

by foreign objects, such as stones or balls, or subject to 
buildup of leaves or sediment.

 WARNING

6" (152 MM) MINIMUM

ABOVE ROOF / 

SNOW LINE

VENT

COM,BUSTION

       AIR

ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24” (610 MM) 
OF VENT PIPE

VENT OUTLET

36” (914 MM) MINIMUM

ABOVE AIR INLET

BIRD SCREEN

(TYPICAL)

Figure 4-2  Stainless Steel Vertical Termination of Air 
and Vent

Follow instructions below when determining 
vent location to avoid possibility of severe 
personal injury, death or substantial property 
damage.

Installation must comply with local 
requirements and with the National Fuel 
Gas Code, ANSI Z223.1 for U.S. installations 
or CSA B149.1 for Canadian installations.

 WARNING

 NOTICE

 WARNING

Do not connect any other appliance to the 
vent pipe or multiple boilers to a common 
vent pipe.  Failure to comply could result in 
severe personal injury, death, or substantial 
property damage.

Determine location

Locate the vent/air terminations using the following guidelines:

1.  The total length of piping for vent or air must not exceed 

the limits given in the General Venting Section on page 21 
of this manual.

2.  The vent must terminate at least 3 feet above the highest 

place in which the vent penetrates the roof and at least 2 feet 
above any part of a building within 10 horizontal feet.

3.  The air piping must terminate in a down-turned 180° 

return pipe no further than 2 feet (.6 m) from the center of 
the vent pipe.  This placement avoids recirculation of flue 
products into the combustion air stream.

4.  The vent piping must terminate in an up-turned coupling 

as shown in FIG. 4-1.  The top of the coupling must be at 
least 1 foot above the air intake.  When the vent termination 
uses a rain cap as illustrated in FIG. 4-2 maintain at least 36"  
(914 mm) above the air inlet.  The air inlet pipe and vent 
pipe can be located in any desired position on the roof, but 
must always be no further than 2 feet (.6 m) apart and with 
the vent termination at least 1 foot above the air intake.

Rooftop vent and air inlet terminations 
must terminate in the same pressure zone, 
unless vertical vent sidewall air is set up as 
shown in the General Venting - Vertical 
Vent, Sidewall Air Section.

Summary of Contents for Sunc 1.0

Page 1: ...staller 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...

Page 2: ...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...

Page 3: ...ntial property damage Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Continual fresh make up water will reduce boiler life Miner...

Page 4: ...isolate the gas valves from the burners 21 Gas shutoff valve outside unit Manual valve used to isolate the gas valve from the gas supply 22 Gas valves The gas valves sense the negative pressure creat...

Page 5: ...3 36 39 37 24 32 2 22 4 1 0 Model Only 25 20 Left Side inside unit 6 23 5 26 14 24 15 29 Right Side inside unit The SYNC How it works continued 5 Models 1 0 1 3 1 5 40 13 1 12 31 28 17 19 42 27 30 34...

Page 6: ...piping and pickup Ratings are based on a piping and pickup allowance of 1 15 3 SYNC boilers require special gas venting Use only the vent materials and methods specified in the SYNC Installation and...

Page 7: ...t connections Failure to follow this warning could result in fire personal injury or death For closet and alcove installations as shown in FIG s 1 1 and 1 2 CPVC or stainless steel vent material must...

Page 8: ...INIMUM CLEARANCE AROUND VENT PIPES Figure 1 1 Closet Installation Minimum Required Clearances WARNING For closet installations CPVC or stainless steel material MUST BE used in a closet structure due t...

Page 9: ...iler Flooring and foundation Flooring The SYNC is approved for installation on combustible flooring but must never be installed on carpeting Vent and air piping The SYNC requires a special vent system...

Page 10: ...st be used at the flue collar connection Size To ensure proper pipe size is in place see Table 2C Check to see that this size is used throughout the vent system Manufacturer For a stainless steel appl...

Page 11: ...tion conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common vent...

Page 12: ...er the air to the equipment room each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu hr 11 cm2 per kW of input see FIG 1 5 IF NECESSARY FOR TIGHT CONS...

Page 13: ...s condition that must be corrected immediately The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance Commo...

Page 14: ...PVC CPVC Two Pipe See Figure 3 1A Stainless Steel Two Pipe See Figure 3 2 Direct venting options Sidewall Vent 2 General venting PVC CPVC Room Air See Figure 4 5 Stainless Steel Room Air See Figure 4...

Page 15: ...eral venting continued Vertical Vent Optional Room Air PVC CPVC Room Air See Figure 4 5 Stainless Steel Room Air See Figure 4 5 PVC CPVC Two Pipe See Figure 4 1 Stainless Steel Two Pipe See Figure 4 2...

Page 16: ...16 PVC CPVC Vertical Vent Sidewall Air Stainless Steel Vertical Vent Sidewall Air Direct venting options Vertical Vent Sidewall Air 2 General venting Installation Operation Manual...

Page 17: ...all requirements of applicable codes Failure to provide a properly installed vent and air system will cause severe personal injury or death All PVC vent pipes must be glued properly supported and the...

Page 18: ...ollow vent pipe manufacturer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the appliance NOTICE The use...

Page 19: ...hird to two thirds into the fitting to ensure proper sealing after cement is applied 6 Priming and Cementing a Handle fittings and pipes carefully to prevent contamination of surfaces b Apply a libera...

Page 20: ...KIT30029 SB 1300 1500 6 PVC x 6 Stainless Steel Adapter 6 Stainless Steel x 7 Stainless Steel Adapters 2 7 Stainless Steel Vent Termination 7 Stainless Steel Air Inlet Table 2B Approved Stainless Stee...

Page 21: ...ler from an existing vent system Vent and air piping Vent and air system Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B...

Page 22: ...ere wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas W...

Page 23: ...tric meter gas meter regulator relief valve or other equipment Never terminate above or below any of these within 4 feet 1 2 m horizontally 6 Locate terminations so they are not likely to be damaged b...

Page 24: ...nt plate see FIG 3 4A Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate 5 Seal all wall cavities Prepare wall penetrations Alte...

Page 25: ...e height to avoid possibility of severe personal injury death or substantial property damage Multiple vent air terminations 1 When terminating multiple SYNC boilers terminate each vent air connection...

Page 26: ...ENT COM BUSTION AIR ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 610 MM OF VENT PIPE VENT OUTLET 36 914 MM MINIMUM ABOVE AIR INLET BIRD SCREEN TYPICAL Figure 4 2 Stainless...

Page 27: ...R DIRECT VENT SYSTEMS REMOVE AIR INLET COVER AND INSTALL RUBBER COUPLING FOR PVC CPVC VENT SYSTEMS OR STAINLESS STEEL ADAPTER FOR STAINLESS STEEL VENT SYSTEMS Figure 4 5 Room Air Installation 3 The ve...

Page 28: ...system returns marked Inlet make sure to install with pipe sealant compound 2 Connect the system supply marked Outlet make sure to install with pipe sealant compound 3 Install purge and balance valve...

Page 29: ...INER RECOMMENDED TYPICAL TEMPERATURE GAUGE RELIEF VALVE CHECK VALVE TYPICAL HEAT EXCHANGER 1 BOILER PUMP SYSTEM PUMP HEAT EXCHANGER 2 BOILER PUMP TO FLOOR DRAIN Figure 5 1A Near Boiler Piping w Y Stra...

Page 30: ...w 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 p...

Page 31: ...all valves could result in a restricted flow rate through the boiler 7 Anti scald mixing valve Field supplied An anti scald mixing valve is recommended when storing domestic hot water above 115 F 46 C...

Page 32: ...EXCHANGER 1 BOILER PUMP Y STRAINER RECOMMEND TYPICAL MAY SUBSTITUTE LOW LOSS HEADER TO SYSTEM TO FLOOR DRAIN FROM SYSTEM Figure 5 5 Single Boiler Primary Secondary Piping NOTICE System flow should al...

Page 33: ...ure 5 6 Multiple Boilers Primary Secondary Piping Model Number of Units 2 3 4 5 6 7 8 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 8 203 8 203...

Page 34: ...b The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than...

Page 35: ...by the gas supplier for 14 inches w c 3 5 kPa maximum pressure 2 Pressure required at gas valve inlet pressure port Maximum 14 inches w c 3 5 kPa with no flow lockup or with boiler on Minimum 8 inche...

Page 36: ...nstaller or service agency to determine the necessary steps to provide proper gas pressure to the control 11 Turn the power switch to the OFF position 12 Shut off the gas supply at the manual gas valv...

Page 37: ...5 kPa maximum for LP gas during standby 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 th...

Page 38: ...x as shown in FIG 7 1 2 Provide and install a fused disconnect or service switch 15 amp recommended as required by the code see FIG 7 1 3 When connecting hot water generator pumps connect the wiring t...

Page 39: ...r cooling from other sources 3 Route sensor wires through a knockout at the rear of the boiler see FIG 7 2 Hot Water Generator HW thermostat 1 Connect the HW tank thermostat to the Tank Thermostat ter...

Page 40: ...5 6 The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system supply sensor see FIG 7 3 The Leader control will use the water temperature at t...

Page 41: ...18 SHIELD GND 17 B 16 A 15 SHIELD GND 14 W 13 R 11 TANK 12 THERMOSTAT 28 B 27 SHIELD GND CASCADE ENABLE A B A B A B BUILDING MANAGEMENT SYSTEM LOUVER PROVING SWITCH TANK THERMOSTAT ENABLING DEVICE SYS...

Page 42: ...t comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement 7 A condensate removal pump is required...

Page 43: ...uire a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may...

Page 44: ...coming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a...

Page 45: ...pressure less than 4 inches w c 99 kPa If none of the above corrects the problem refer to the Troubleshooting Section of the SYNC Service Manual Check system and boiler Check water piping 1 Check syst...

Page 46: ...ian to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label...

Page 47: ...set point temperatures can be adjusted from the Set Points Menu Press the following buttons to navigate to the Set Points Menu from the Status Screen 1 To change a set point press the SELECT button ne...

Page 48: ...e boiler is installed and anytime the boiler has been powered off for more than one month Use the following procedure to set the clock 1 To set the clock press the SELECT button in the upper right han...

Page 49: ...lls for heat the control modules activate the HW pumps shuts down the boiler pumps and immediately sets the target outlet water temperature to 180 F 82 2 C This provides automatic priority heat alloca...

Page 50: ...re is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 185 F the unit will reduce the fan speed If the outlet water temperature exceeds 195 F 90 C the control will...

Page 51: ...the outdoor sensor is not installed Target temperature is calculated as described below under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected High limit opera...

Page 52: ...f This will continue until the demand is satisfied and all boilers are shut off HW operation with cascade For HW operation any boiler s in the Cascade can be selected to provide heat for a HW call Sel...

Page 53: ...int temperature 9 If the current call for heat is for space heating and a HW call for heat becomes active the control will turn on the HW pump relay output then turn off the boiler pumps It will then...

Page 54: ...m 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 HW Storage The boiler has received a hot water gener...

Page 55: ...the temperature as measured by the tank sensor in the hot water storage tank Time The time is displayed in the upper right hand corner of the display It is displayed in 24 hour format Reference the S...

Page 56: ...s used in the boiler Building Shows the information from a Building Integration System using Modbus Protocols Graphs Allows the selection of items to be graphed on a chart History Shows the operating...

Page 57: ...inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F 30 C above return water temperature Test low water flow conditi...

Page 58: ...If they cannot be removed reinstall the air and vent lines per this manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuum any sediment from in...

Page 59: ...ping before proceeding further Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product...

Page 60: ...nd wiring 1 Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip 2 Verify all wiring is in good condition and securely attached 3 Check ground continuity of wiring...

Page 61: ...er while dry using a nylon bristle brush Caution DO NOT use a metal brush Re vacuum the heat exchanger 8 Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressu...

Page 62: ...cing the ceramic materials it is advisable that the installer follow these safety guidelines Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of re...

Page 63: ...N HIGH VOLTAGE SPARK LEAD BLOWER X2 2 FLAP VALVE AIR PRESSURE SWITCH FLAP VALVE X5 7 24V X5 7 24V X5 4 X5 4 INLET SENSOR INLET SENSOR OUTLET SENSOR FLUE SENSOR OUTLET SENSOR FLUE SENSOR HI LIMIT HI LI...

Page 64: ...RELAY HEX 1 BOILER PUMP CONTACTS HEX 2 BOILER PUMP CONTACTS SYSTEM PUMP CONTACTS L1 N L2 120 VAC 24 VAC ON OFF SWITCH X1 6 BOILER PUMP RELAY DHW PUMP RELAY SYSTEM PUMP RELAY BLOWER RELAY X1 4 X1 2 X1...

Page 65: ...12 CN1 15 CN1 16 CN1 8 CN1 7 CONNECTION BOARD JUNCTION BOX RELAY BOARD K1 K2 K3 X8 MOD BUS KIT X4 X6 6 X6 1 LOW WATER CUTOFF BOARD J3 1 J3 2 J3 3 J3 4 J3 5 J3 6 J2 1 J2 2 J2 3 X6 2 X6 9 X6 10 BLOWER G...

Page 66: ...66 Notes...

Page 67: ...67 Notes...

Page 68: ...moval of the stabilitor from FIG 11 2 C04057 and placing the illustrations disclaimer on all the piping drawings ECR R02431 Revision F ECO C04560 reflects the addition of Modbus to the manual new heat...

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