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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.

Contents

HAZARD DEFINITIONS .....................................................  2
PLEASE READ BEFORE PROCEEDING .........................  3
1.  PREVENT COMBUSTION AIR CONTAMINATION .....  4
2.  MAINTENANCE SCHEDULE .......................................  5
Maintenance Procedures ...................................................  6
     Boiler Must Be Serviced and Maintained ....................   6
     Check Boiler Area .........................................................  6
     Check Pressure Temperature Gauge ...........................  6
     Check Vent Piping ........................................................  6
     Check Air Piping ...........................................................  6
     Check Relief Valve .......................................................  6
     Check Condensate Drain System ................................  6
     Check Air Vents ............................................................  7
     Test Low Water Cutoff (if installed) ..............................  8
     Reset Button (low water cutoff) ....................................  8
     Check Boiler Piping (gas and water) ............................  8
     Operate Relief Valve ....................................................  8
     Shut Boiler Down ..........................................................  8

3.  OPERATING INSTRUCTIONS .....................................  9
4.  SMART TOUCH CONTROL MODULE
     SYNC Control Module ................................................  10
     Status Screen ........................................................ 10-11
     Details Screen ....................................................... 12-13
     Main Menu Screen .....................................................  14
NOTES   ...........................................................................  15
Revision Notes ................................................... Back Cover

Summary of Contents for SYNC 1.0

Page 1: ...trical switch do not use any phone in your building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING If the information in these instructions is not followed exactly a fire or expl...

Page 2: ...ch 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 Contents HAZARD DEFINITIONS 2 PLEASE READ BEFORE PROCEEDING 3 1 PREVENT COMBUSTION AIR CONTAMINATION 4 2 MAINTENANCE SCHEDULE 5 Maintenance Procedures 6 Boiler Must Be Serviced and Maintained 6 Check ...

Page 3: ...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 Boiler water Thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment Do not use petroleum based...

Page 4: ...ools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops Table 1A Corrosive Contaminants and Sources WARNING If the boiler combustion air inlet is located in any area likely to cause contamination or if pr...

Page 5: ...ion Check wiring and connections Perform start up checkout and performance verification per Section 9 Flame 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 conditions If combustion or performance indicate need Clean heat exchanger Remove and clean burner ...

Page 6: ...nate the boiler intake air will cause acidic condensate in the boiler This will cause significant damage to the boiler if allowed to continue Read the list of potential materials listed in Table 1A on page 4 of this manual If any of these products are in the room from which the boiler takes its combustion air they must be removed immediately or the boiler combustion air and vent termination must b...

Page 7: ...bow field provided as shown in FIG 2 2 5 Do not expose condensate line to freezing temperatures Use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must 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 6 A condensate removal pump ...

Page 8: ...or discharge line may be blocked Immediately shut down the boiler following the operating instructions on page 9 of this manual Call your qualified service technician to inspect the boiler and system Shut boiler down unless boiler is used for Domestic Water 1 Follow To Turn Off Gas to Appliance on page 9 of this manual 2 Do not drain the system unless exposure to freezing temperatures will occur 3...

Page 9: ...spect 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 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner b...

Page 10: ...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 generation call HW Pump Delay The boiler has satisfied a hot water generation call and the hot water generator pumps are running for a fixed time to remove any residual heat SH BMS The boiler has received a call for heat from a 0 1...

Page 11: ...s 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 Night Setback parameters in the SYNC Service Manual for information regarding adjusting the date and time Details button Pressing this button brings up the Details Screen This screen shows the status of the various safe...

Page 12: ...gh and low gas pressure switches are closed If OFF when either the high or low gas pressure switches are open Flow Switch Low Water Cutoff Is ON when the low water cutoff contacts are closed or if an optional flow switch is used and it is closed as well Is OFF when the low water cutoff contacts are open or if an optional flow switch is open Alarm Is ON when a fault has been detected and the alarm ...

Page 13: ...w The 120 VAC input to the control has dropped below 80 VAC Reference the SYNC Service Manual for more information regarding this fault message Connect System Sensor System sensor is not detected by Control Module 1 For proper operation of the SYNC boiler the system sensor must be connected Manual Shutdown The boiler has been shutdown with the ON OFF button on the Status Screen Time The time is di...

Page 14: ...om a Building Integration System using Modbus Protocols Graphs Allows the selection of items to be graphed on a chart History Shows the operating and fault history of the two 2 control modules Service Mode Allows the installer to control the fan speed of the individual control modules for the purposes of combustion analysis Service Mode will override all other heat demands however all safeties wil...

Page 15: ...15 Notes ...

Page 16: ... change from automatic air vent to manual air vent The chart on page 5 was updated and a new image of the air vent valve was inserted on page 8 FIG 3 Revision D ECO C07072 reflects the change in design of the manual air vent and the update of FIG 2 3 on page 8 Revision E ECO C14411 reflects changes made to the condensate trap R6594 along with the addition of the corrosive contaminant warning on pa...

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