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SYNC 1.0 - User Manual

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Installation & Operation Manual
Models: 1.0 - 1.3 - 1.5
This manual must only be used by
a qualified heating installer / 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 injury, death, or
substantial property damage.
WARNING
Save this manual for future reference.
SYNC-I-O Rev U_2000017704_100161722

Table of Contents

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Summary

The SYNC - How it works

Ratings

Determine boiler location

Closet and alcove installations

Guidelines for installing the boiler in closets or alcoves, including required clearances and materials.

Provide clearances

Specifies minimum clearances required around the boiler for safety and service access.

Air and Ventilation Requirements

Details requirements for air openings and ventilation for proper combustion and operation.

Flooring and Foundation Considerations

Specifies requirements for the boiler's installation surface, prohibiting carpeting.

Vent and Air Piping Placement

Guidance on routing and terminating vent and air piping systems to ensure proper function.

Combustion Air Contamination Prevention

Lists contaminants to avoid and areas to prevent intake air contamination to protect the boiler.

Existing Vent System Installation

Procedures and checks for using an existing vent system to install a new boiler.

Boiler Removal and Handling

Instructions for removing an old boiler and handling the new unit from its shipping pallet.

General venting

Direct Venting Options

Illustrates sidewall and vertical direct venting configurations for air and vent.

Install Vent and Air Piping

Instructions for installing vent and combustion air piping, including material requirements.

Venting Materials and Requirements

Details approved materials like PVC/CPVC, Polypropylene, and Stainless Steel for venting.

Optional Room Air Installation

Guidelines for using room air for combustion instead of direct outside air.

Vent Pipe Sizing and Specifications

Provides tables for air intake and vent piping sizes based on model and length.

Sidewall direct venting

Vent;Air Termination - Sidewall

Instructions and diagrams for terminating vent and air pipes through a sidewall.

Determine Sidewall Location

Guidelines for selecting the optimal location for sidewall terminations.

Prepare Wall Penetrations

Steps for cutting holes in the wall and mounting termination plates.

Vertical direct venting

Vent;Air Termination - Vertical

Diagrams and instructions for terminating vent and air pipes through a roof.

Determine Vertical Location

Guidance on selecting the appropriate roof location for vertical terminations.

Prepare Roof Penetrations

Steps for creating roof openings and installing flashing for vent and air pipes.

Hydronic piping

System Water Piping Methods

Describes requirements for closed-loop pressurized systems and air elimination.

General Piping Information

Outlines basic steps and components for system piping installation.

Near Boiler Piping Connections

Illustrates typical piping configurations near the boiler, including strainers and pumps.

Hot Water Generator Pump Sizing

Provides guidance and examples for sizing pumps for the HW generator loop.

Gas connections

Connecting Gas Supply Piping

Instructions for connecting the gas supply, including unions, drip legs, and shutoff valves.

Check Inlet Gas Supply

Procedures for checking gas supply pressure and ensuring proper operation.

Gas Pressure Requirements

Specifies minimum and maximum pressure requirements for natural and propane gas.

Field wiring

Line Voltage Connections

Instructions for connecting the primary 120 VAC power to the boiler.

Low Voltage Wiring

Details connecting low voltage wires to the control board for sensors, thermostats, and inputs.

System and Cascade Wiring

Covers wiring for system sensors, boiler management, and multi-boiler cascade configurations.

Condensate disposal

Condensate Drain Installation

Instructions for connecting the condensate drain line, including neutralization and trap filling.

Start-up

Water System Preparation

Steps for filling the system, checking water chemistry, and purging air.

Gas System Checks

Procedures for checking for gas leaks and verifying gas supply.

Flame and Combustion Checks

Guidance on checking burner flame, combustion analysis, and safety shutoff devices.

Operating Instructions

Step-by-step guide for safely starting up the boiler and checking its operation.

Set Operation Modes

How to configure and adjust settings for space heating and HW generation.

Configuration Procedures

Instructions for setting the clock and configuring cascade operation.

Operating information

Boiler Operation and Control

Explains boiler, control modules, inputs, outputs, and operational features like HW priority.

Control Functions and Protection

Details settings like gradient limiting, outdoor reset, night setback, and safety features.

System Management and Cascade

Covers cascade operation, sequence, system sensors, and safety limits.

Interface Screens and Navigation

Describes the Status Screen and Main Menu for user interaction and monitoring.

Maintenance

Service Technician Procedures

Outlines tasks for annual start-up and routine maintenance by a qualified technician.

Owner Maintenance Tasks

Lists daily, monthly, and periodic maintenance tasks for the owner.

Boiler System Checks

Covers checks for piping leaks, flue vent system, water system, and relief valve.

Ignition and Flame Checks

Procedures for inspecting and cleaning ignition electrodes and checking burner flame.

Heat Exchanger Cleaning

Detailed steps for cleaning the boiler's heat exchanger.

Handling Ceramic Fiber Materials

Safety guidelines for handling insulation materials within the combustion chamber.

Diagrams

Ladder Diagrams

Illustrates the electrical logic and connections of the boiler's control system.

Wiring Diagram

Provides a detailed schematic of all electrical connections within the boiler.

SYNC 1.0 Specifications

General IconGeneral
BrandSYNC
Model1.0
CategoryBoiler
LanguageEnglish