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2  

Maintenance schedule

8

 WARNING

Have leaks fixed at once by a qualified 
service technician.  Failure to comply could 
result in severe personal injury, death, or 
substantial property damage.

Operate relief valve

1.  Before proceeding, verify that the relief valve outlet has 
 

been piped to a safe place of discharge, avoiding any 

 

possibility of scalding from hot water.

 WARNING

To avoid water damage or scalding due 
to valve operation, a metal discharge 
line must be connected to the relief 
valve outlet and run to a safe place of 
disposal.  This discharge line must be 
installed by a qualified heating installer 
or service technician in accordance with 
the instructions in the SYNC Installation 
and Operation Manual.  The discharge 
line must be terminated so as to eliminate 
possibility of severe burns or property 
damage should the valve discharge.

2.  Read the boiler pressure/temperature gauge to make 
 

sure the system is pressurized.  Lift the relief valve 

 

top lever slightly, allowing water to relieve through 

 

the valve and discharge piping.

3.  If water flows freely, release the lever and allow the valve 
 

to seat.  Watch the end of the relief valve discharge pipe 

 

to ensure that the valve does not weep after the line has 

 

had time to drain.  If the valve weeps, lift the seat again to 

 

attempt to clean the valve seat.  If the valve continues to 

  weep afterwards, contact your qualified service 
 

technician to inspect the valve and system.

4.  If water does not flow from the valve when you lift the 
 

lever completely, the valve 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.  Do not drain the system if it is filled with an antifreeze 
 solution.

4.  DO NOT shut down boilers used for domestic water 
 

heating, they must operate year-round.

3.  Replace the front access door.

Test low water cutoff (if installed)

1.  If the system is equipped with a low water cutoff, test the 
 

low water cutoff periodically during the heating season, 

  following the low water cutoff manufacturer’s 
 instructions.

Reset button (low water cutoff)

1.  Testing the low water cutoff shuts the unit off.   Press the 
 

RESET button on the low water cutoff to turn the unit 

 back 

on.

Check boiler piping (gas and water)

1.  Remove the boiler front access door and perform a gas 
 

leak inspection per steps 1 through 7 of the Operating 

 

Instructions on page 9.  If gas odor or leak is detected, 

 

immediately shut down the boiler following the 

 

procedure on page 9.  Call a qualified service technician.

2.  Visually inspect for leaks around water piping. 

 

 

Also inspect the  circulators, relief valve, and fittings.  

 

Immediately call a qualified service technician to repair 

 any 

leaks.

MANUAL 

AIR VENT VALVE

Figure 2-3 Air Vent

Check air vents

1. Reference 

FIG. 

2-3 

below.

2.  Visually inspect the vent to make sure that no leaks are 

present.

3.  If there is leaking, tighten the pin valve. 

4.  If the leaking continues, replace the air vent.

                  

User’s Information Manual 

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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