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32

Installation & Operation Manual

5

Hydronic piping

HOT WATER
GENERATOR

SYSTEM
CIRCULATOR

AIR
SEPERATOR

MAKE UP
WATER

DRAIN POINT
(TYPICAL)

SYSTEM SUPPLY
SENSOR

BALL VALVE
(TYPICAL)

HEAT EXCHANGER 2
BOILER PUMP

PRESSURE RELIEF
VALVE

FLOW CHECK
VALVE (TYPICAL)

PRESSURE REDUCING
(VALVE)

EXPANSION
TANK

UNION (TYPICAL)

TEMPERATURE/
PRESSURE GAUGE

WATER GENERATOR
CIRCULATOR
(TYPICAL)

BACK FLOW
PREVENTER

PRESSURE GAUGE

HEAT EXCHANGER 1
BOILER PUMP

Y-STRAINER

(RECOMMEND)

(TYPICAL)

MAY SUBSTITUTE LOW LOSS HEADER

TO

SY

STE

M

TO FLOOR
DRAIN

FR

OM

SY

STE

M

Figure 5-5 Single Boiler - Primary/Secondary Piping

NOTICE

System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.

NOTICE

A system supply sensor (factory
supplied) MUST BE installed for proper
boiler operation.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.

NOTICE

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Содержание Sunc 1.0

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 66: ...66 Notes...

Страница 67: ...67 Notes...

Страница 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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