SYNC-SER Rev H
Service Manual
Models: 1.0, 1.3, and 1.5
This manual must only be
used by a qualified heating
installer / service technician.
ƽ WARNING
Read
all
instructions,
including this manual and
the SYNC Installation and
Operation Manual, before
installing. Perform steps in
the order given. Failure to
comply could result in severe
personal injury, death, or
substantial property damage.
Save this manual for future reference.
Service Manual
Handling ceramic fiber materials
REMOVAL OF COMBUSTION CHAMBER LINING
The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can
be converted to cristobalite in very high temperature applications. The International Agency for Research
on Cancer (IARC) has concluded, “Crystalline silica in the form of quartz or cristobalite from occupational
sources is carcinogenic to humans (Group 1).” Normal operating temperatures in this appliance are below
the level to convert ceramic fibers to cristobalite. Abnormal operating conditions would have to be created
to convert the ceramic fibers in this appliance to cristobalite.
ƽ WARNING
The ceramic fiber material used in this appliance is an irritant; when handling or replacing 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 respirator is based on the OSHA
requirements for cristobalite at the time this document was written. Other types of respirators may
be needed depending on the job site conditions. Current NIOSH recommendations can be found on
manufacturers, and phone numbers are also listed on this website.
• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.
Apply enough water to the combustion chamber lining to prevent airborne dust.
Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.
Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer
thoroughly.
NIOSH stated First Aid.
Eye: Irrigate immediately.
Breathing: Fresh air.
Boiler water –
When servicing boiler –
• 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.
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
• Do not use petroleum-based cleaning or sealing
compounds in the boiler system. Gaskets and seals in
the system may be damaged. This can result in
substantial property damage.
Boiler operation –
• Do not block flow of combustion or ventilation air to
the boiler.
• Do not use “homemade cures” or “boiler patent
medicines”. Serious damage to the boiler, personnel,
and/or property may result.
• Should overheating occur or gas supply fail to shut
off, do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a
location external to the appliance.
• Continual fresh make-up water will reduce boiler
life. Mineral buildup in the heat exchanger reduces
heat transfer, overheats the stainless steel heat
exchanger, and causes failure. Addition of oxygen
carried in by makeup water can cause internal
corrosion. Leaks in boiler piping must be repaired at
once to prevent the introduction of makeup water.
• Do not use 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.
Freeze protection fluids –
• NEVER use automotive antifreeze.
Use only
inhibited propylene glycol solutions which are
specifically formulated for hydronic systems.
Ethylene glycol is toxic and can attack gaskets and
seals used in hydronic systems.
3
Service Manual
What is in this manual?
Service
Maintenance
• Service and maintenance schedules
• Address reported problems
• Inspect boiler area and boiler interior
• Clean condensate trap
• Check all piping for leaks
• Check air openings
Near boiler piping
• Typical system components
The SMART TOUCH display
• Touch screen readout, buttons and their functions
• Flue vent system and air piping
• Check water system
• Check expansion tank
Control module inputs
• Control module inputs and options
• Check boiler relief valve
• Inspect ignition electrode
• Check ignition ground wiring
• Check all boiler wiring
• Check control settings
• Perform start-up and checks
• Check burner flame
• Check flame signal
• Check flue gas temperature
• General maintenance
Control module outputs
• Control module outputs and options
General
• How the boiler operates
• How the control module operates
• Access modes -- user and installer
• Sequence of operation -- Hot Water Generation
(HW)/space heating
• Review with owner
Control panel menu access
• Cleaning boiler heat exchanger
• Oiled bearing circulators
•
A c c e s s i n g
p r o g r a m m i n g
mode and locating menus
(See separate guides covering the PC interface.)
Troubleshooting
Control panel parameter access
• Troubleshooting table - No display
• Checking temperature sensors
• Sensor tables
• Accessing and changing parameters from the touch screen
Quick start information -- parameter
table
• Troubleshooting table - Fault messages displayed on
boiler interface
• Combustion analysis procedure
• Gas valve adjustment procedure
• An index of available adjustments and readouts, where to
access them and where to find detailed information.
SYNC operation
• Service / Setup
• Set Points
• Outdoor Reset
• Night Setback
• Cascade
• Pumps
• BMS
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Service Manual
1 Service
Near boiler piping
This piping reference is included to specify the Near Boiler Piping specific to the SYNC. This piping scheme is important for
proper operation of the SMART TOUCH control module. See the SYNC Installation and Operation Manual for more detailed
piping diagrams.
DRAIN (TYPICAL)
SYSTEM SUPPLY SENSOR
(NOTICE: A SYSTEM SUPPLY
SENSOR MUST BE INSTALLED FOR
PROPER BOILER OPERATION.)
SYSTEM PUMP
ISOLATION VALVE
(TYPICAL)
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
TEMPERATURE GAUGE
HEAT EXCHANGER 1
BOILER PUMP
RELIEF VALVE
HEAT EXCHANGER 2
BOILER PUMP
TO FLOOR DRAIN
CHECK VALVE
(TYPICAL)
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Service Manual
1 Service
The SYNC display
6
Service Manual
1 Service
(continued)
Control inputs
SECONDARY
SMART CONTROL
MODULE
LOW VOLTAGE
CONNECTION
BOARD
PRIMARY
SMART CONTROL
MODULE
SEQUENCER / BUILDING
MANAGMENT SYSTEM
O-TEMP
OUTDOOR SENSOR
HEAT EXCHANGER SWITCH
HW TANK SENSOR
SYSTEM SENSOR
PRIMARY/SECONDARY INLET
TEMPERATURE SENSOR
O-TEMP
HEAT EXCHANGER SWITCH
PRIMARY/SECONDARY OUTLET
TEMPERATURE SENSOR
FLOW SWITCH
BLOCKED DRAIN SWITCH
HW THERMOSTAT
PRIMARY/SECONDARY
FLUE GAS SENSOR
ROOM THERMOSTAT /
ZONE CONTROL
LOW WATER CUTOFF
TOUCH PANEL
PRIMARY/SECONDARY
GAS PRESSURE SWITCH
INTERFACE
TOUCH DISPLAY
PRIMARY/SECONDARY
HIGH LIMIT SENSOR
PRIMARY/SECONDARY
FLAME SENSOR
MODBUS COMMUNICATION
BOARD
PC INTERFACE
IMG00004
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Service Manual
1 Service
Control outputs
SECONDARY
SMART TOUCH
LOW VOLTAGE
CONNECTION
BOARD
CONTROL MODULE
PRIMARY
SMART TOUCH
CONTROL MODULE
ALARM BELL
RUN TIME CONTACTS
HEAT EXCHANGER 1 /
HEAT EXCHANGER 2
BOILER PUMP
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
SYSTEM PUMP
TOUCH PANEL
HW PUMP
IGNITOR
TOUCH DISPLAY
INTERFACE
PC INTERFACE
BLOWER
GAS VALVE
8
Service Manual
1 Service
(continued)
General Operation
How the boiler operates
Access modes
The SYNC uses two (2) advanced stainless steel heat User
exchangers and two (2) electronic control modules that allow
fully condensing operation. The blowers pull in gas and air The user can view all of the settings on the LCD screen. By
and push flue products out of the boiler through the heat entering the user password (0704), the user can adjust the
exchangers and flue piping. The control modules regulate User Set Point, Outdoor Shutdown, Night Setback, Boost,
blower speeds to control total boiler firing rate. The gas HW Boiler Output Set Point, Backlight Time, and Backlight
valves sense the amount of air flowing into the boiler and Brightness settings.
allow only the right amount of gas to flow.
Installer
How the control module operates
Most parameters are available only to the installer, accessible
only by entering the installer access code (5309).
The SYNC control modules receive input from boiler sensors.
The control modules activate and control the blower and
gas valves to regulate heat input and switches boiler, Hot
Water Generation (HW) and system pumps on and off as
needed. The user/installer programs the control module to
meet system needs by adjusting control parameters. These
parameters set operating temperatures and boiler operating
modes.
Sequence of operation
Table 1A shows control module normal sequences of
operation for space heating and HW operation for each
individual control module. Additionally, the control
modules are programmed to synchronize their combined
modulation rates in order to maximize total boiler efficiency.
The combined operation sequence is for a typical application,
programmed to provide HW priority.
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Service Manual
1 Service
Sequence of operation
Table 1A Sequence of operation - space heating and HW
Note: This unit is equipped with two (2) independent, but synchronized combustion systems. Heat Exchanger 1 (top)
combustion system will fire first. If the demand cannot be met by one (1) combustion system the same sequence of operation
will be followed to bring the Heat Exchanger 2 combustion system online.
Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for a space heating call,
HW pump relay output for a HW call).
1.
The control confirms that the low water cutoff and flow switch (optional) contacts are closed.
2.
The control starts the blower and closes the louver contacts to begin the Pre-Purge cycle.
3.
The control confirms that the blower comes up to the desired speed, the flap valve opens, and the air pressure switch,
gas pressure switches, louver proving switch (field installed), and blocked drain switch contacts close.
4.
Once the Pre-Purge cycle is complete, the control lowers the blower speed, initiates sparking of the ignition electrode,
and opens the gas valve.
5.
After a short wait, the control stops sparking and checks for the presence of flame current through the spark and
flame sense electrodes.
6.
If the control does not detect flame current, the control will lockout, until the RESET button on the touch screen
LCD is pressed.
7.
If the control detects flame current, the control will hold the blower speed constant for a few seconds to allow the
flame to stabilize, then begin modulating the firing rate in order to maintain the controlling sensor to the desired set
point temperature.
8.
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 modulate the blower speed in order to maintain the
outlet temperature to the desired HW outlet set point temperature.
9.
If the first heat exchanger in the boiler is unable to maintain the desired set point temperature, the second heat
exchanger in the boiler will be started, using much of the same sequences as described above. Once both heat
exchangers are firing, the controls will work in synchronization to maintain the desired set point temperature. If
the heat load should decrease sufficiently, the second heat exchanger will be shut down, much like the sequences
described below.
10.
Once both the space heating and HW calls for heat are satisfied, the control will turn off the gas valve and begin the
Post-Purge cycle. Any pumps that are running will begin their respective Pump Delay cycles.
11.
At the end of the Post-Purge cycle, the louver contacts will open.
12.
The control verifies that the blower stops running and the flap valve closes.
13.
At the end of the Pump Delay cycle(s), the pumps will be turned off.
14.
10
Service Manual
1 Service
(continued)
Parameter table
Table 1B This table lists the parameters and where to access them
USER ACCESS
INSTALLER ACCESS
SEE
MENU
DESCRIPTION
PAGE
DISPLAY
MODIFY
Yes
DISPLAY
MODIFY
Yes
Service/Setup
18
18
18
18
18
18
18
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Night Setback
Set points
Cascade
Yes
Yes
Yes
Yes
Yes
Yes
Outdoor Reset
Pumps
Yes
Yes
Yes
Yes
BMS
Yes
Yes
Demand Conf
Serv Not Time
Serv Not Run H
Serv Not Cycl
Ramp Delay
Max Serv T
19
19
19
19
19
20
20
20
20
20
Yes
No
No
No
No
Yes
No
No
No
No
No
No
No
No
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
No
Temp Unit
Yes
Yes
Yes
Yes
User Passwd
LCD Backlight
LCD Bright
User setp
SH off df
21
21
No
No
No
No
Yes
Yes
Yes
Yes
SH off/on df
Tank setp
21
21
21
21
21
21
21
21
21
21
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Tank off/on df
Indirect HW setp
SH/HW sw tim
NSB setp
Min User setp
Max User setp
Drop in Inlet
Anti-C t
11
Service Manual
1 Service
Table 1B (continued from previous page) This table lists the parameters and where to access them
USER ACCESS
DISPLAY MODIFY
INSTALLER ACCESS
SEE
MENU
DESCRIPTION
PAGE
DISPLAY
Yes
MODIFY
No
Reset T Lo Out
22
22
22
22
22
22
22
23
Yes
No
Reset T Hi Out
Out T Hi Reset
Out T Lo Reset
Out SD setp
Out SD df
Yes
No
No
No
No
No
No
Yes
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Boost tim
Yes
Yes
Boost incr
Yes
Yes
Date and time
24
24
Yes
No
Yes
No
Yes
Yes
Yes
Yes
On Timer and Off Timer
Casc Address
Casc off df
25
25
25
25
Yes
No
No
No
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Casc off/on df
Max Outl temp
Boiler Pump D
HW Pump D
26
26
26
26
Yes
No
No
No
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Sys Pump D
Sys Pump mode
BMS Type
27
27
27
27
27
27
27
28
28
28
28
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
BMS Setp min V
BMS Setp max V
BMS V min Setp
BMS V max Setp
BMS V Heat
Dropin BMS End
BMS mod@minV
BMS mod@maxV
BMS V @min mod
BMS V @max mod
12
Service Manual
1 Service
(continued)
Viewable and changeable control parameters
Status Screen:
When the ON/OFF switch is turned to the ON position,
the first screen visible on the LCD display will be the Status
Screen. This screen displays the current status of the SYNC
boiler. The following items can be viewed or interacted with
on the Status Screen:
• SH BMS - The boiler has received a call for heat from
a 0-10 VDC BMS control.
• Service Set Point Met - While in Service Mode, the
water temperature at either the outlet sensor or the
system sensor has exceeded 185°F.
• HW Outlet Set Point Met
temperature has exceeded the HW Generator Set Point
parameter.
-
The outlet water
On/Off button - Pressing this button allows the boiler to be
placed in either Manual Shutdown Mode or Standby Mode.
• OA Shutdown - The outside air temperature has
exceeded the Outdoor Shutdown Set Point parameter.
• SH Set Point Met - The water temperature as measured
by the system supply sensor has exceeded the User Set
Point parameter or if the optional Outdoor Air Sensor
was used, the calculated set point based on the
Outdoor Reset parameters.
Boiler Status - This line shows the current operating status of
the SYNC boiler. Displayed items are as follows:
• Manual Shutdown
-
The boiler will not
respond to either a system call or a hot water
generation call.
• Standby - The boiler has not received a system call
or hot water generation call.
• Anti-Cycle Delay - The boiler has satisfied a system
heat call, but has received another system heat call
before the anti-cycling time parameter has elapsed.
• Cascade ComError - A communication error has occurred
between the Control Module 1 and Control Module 2 or
between the Leader and Member boilers.
• SH Call for Heat - The boiler has received a system 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
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.
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1 Service
Hot Water Tank Temperature - This is the temperature as
Boiler Configuration - This line shows the current
measured by the tank sensor in the hot water storage tank.
configuration of the two control modules inside the unit.
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 on page 24 for information regarding
adjusting the date and time.
Outlet Water Temperature - This is a calculated temperature
based on the readings of the outlet temperatures of the two
(2) heat exchangers.
System Water Temperature - This is the water temperature
as measured by the system supply sensor located in the
downstream piping.
Details button - Pressing this button brings up the Details
Screen. This screen shows the status of the various safeties,
inputs, and outputs to each control module. Reference the
Details Screen section on page 15 for more information
regarding this screen.
Inlet Water Temperature - This is a calculated temperature
based on the inlet temperature readings from the two (2) heat
exchangers.
Main button - Pressing this button brings up the Main Screen.
From this screen navigation to eight (8) other screens is
possible. Reference the Main Screen section on page 17 of this
manual for more information regarding this screen.
14
Service Manual
1 Service
(continued)
Details Screen:
• Alarm - Is ON when a fault has been detected and the
alarm contacts are closed. Is OFF when the alarm
contacts are open.
• Louver Proving Switch - Is ON when a remote proving
safety switch is closed. Is OFF when a remote proving
safety switch is open.
The Details Screen is accessed by pressing the DETAIL button
on the Status Screen. This screen shows the status of the
various safeties, inputs and outputs to each control module.
Selection of the control module to be viewed is accomplished
by pressing the SELECT button. The control module being
displayed is shown in the module box.
• Blocked Drain Switch - Is ON when the blocked drain
switch on the condensate trap is closed. Is OFF when the
blocked drain switch on the condensate trap is open.
• Blower Power - Is ON when the combustion air blower is
energized. Is OFF when the combustion air blower is de-
energized.
• System Pump - Is ON when a system heat call has been
received and the system pump has been energized. Is
OFF when the system pump is de-energized.
• Auto Reset High Limit - An auto reset high limit is not used
in the standard configuration of the SYNC boiler. If OFF is
shown then a wiring problem exists.
• Run Time Contacts - Is ON when the burner is energized.
Is OFF when the burner is de-energized.
• HW Pump - Is ON when a Hot Water Generation call has
been received from a tank thermostat or a tank sensor and
the hot water generation pump is energized. Is OFF when
the hot water generation pump is de-energized.
• 0-10Vdc - Shows the voltage signal being delivered from a
remote Building Management System (BMS).
Displayed items are as follows:
• SH Enable - Is ON when a system heat call has been
received from a remote end switch or enabling device. Is
OFF when a system heat call is not present.
• Manual Reset High Limit - Is ON when the manual reset
high limit is closed. Is OFF when the manual reset high
limit is open.
• SH Pump - Is ON when a system heat call has been
received and the boiler pump is energized. Is OFF
when the boiler pump is de-energized.
• HW Thermostat - Is ON when a Hot Water Generation
call has been received from a tank thermostat. Is OFF
when a Hot Water Generation call has not been received
from a tank thermostat.
• Air Pressure Switch - Is ON when the combustion air
blower is energized and the flap valve switch is closed.
Is OFF when the flap valve switch is open.
• Gas Valve - Is ON when the gas valve is energized. Is OFF
when the gas valve is de-energized.
• Gas Pressure Switches - Is ON when the high 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.
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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 on page 24 for information regarding
adjusting the date and time.
A blank message box is located on the Details Screen. This
box will display various messages detailing the status of the
control module. If a message is present in this box, the
DETAILS button on the Status Screen will contain a yellow
triangle with an exclamation mark (!) inside.
Status button - Pressing this button displays the Status Screen.
This screen shows the current status of the SYNC boiler.
Reference pages 13 - 14 for more information regarding this
screen.
Displayed items are as follows:
• Delta T Shutdown - The temperature rise between the
inlet and outlet temperatures has exceeded 55°F.
Reference page 53 for more information regarding this
shutdown.
• Outlet Temp Shutdown - The outlet temperature has
exceeded 195°F. Reference page 53 for more information
regarding this shutdown.
Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) additional screens is
possible. Refer to Main Screen on page 17 for more information
regarding this screen.
• Flue Temp Shutdown - The flue temperature has
exceeded 240°F. Reference page 53 for more information
regarding this shutdown.
• Voltage too Low - The 120 VAC input to the control has
dropped below 80 VAC. Reference page 52 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.
16
Service Manual
1 Service
(continued)
Main Screen:
The Main Screen allows navigation to eight (8) additional Navigation to the Main Screen can be accomplished by pressing
screens which are used to set temperatures, operating the MAIN button at the bottom of the page.
conditions, and monitor boiler operation. These screens are
Reference pages 18 - 35 of this manual for more information
as follows:
regarding the eight (8) accessible screens.
• Setup - Allows access to seven (7) other screens for the
adjustment of the control parameters.
Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in 24 hour format. Reference the
• Cascade - Shows the status of multiple boilers connected
night setback parameters on page 24 for information regarding
together in a cascade arrangement.
adjusting the date and time.
• Temps - Shows the temperatures measured by the
individual sensors connected to the boiler.
• Burners - Shows the status of the two (2) independent
burner systems 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.
Status button - Pressing this button displays the Status Screen.
This screen shows the current status of the SYNC boiler.
Reference pages 13 - 14 for more information regarding this
screen.
• 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 will remain
intact.
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Service Manual
1 Service
Before changing parameters, note the settings so that the unit can be returned to its original operating
parameters.
CAUTION
Setup Screen:
The Setup Screen allows access to seven (7) other screens for If the password has been entered correctly, the Parameter
adjusting control parameters.
Change Screen will appear. The Parameter Change Screen will
display the parameter being changed, the previous setting of the
parameter, and adjustment buttons.
These screens are as follows:
• Service / Setup - Allows access to change service
notification parameters, LCD backlight parameters, and
temperature units.
• Night Setback - Allows access to change the date and time
and ON/OFF times for night setback.
• Setpoints - Allows access to change the system heat
set point, hot water generation set point, and ON/OFF
differentials.
• Cascade - Allows access to change the cascade parameters.
• Outdoor Reset - Allows access to change the reset curve
parameters.
To adjust the parameter, press the + or - buttons to change the
value being displayed. Once the parameter has been adjusted
to the desired setting, press the APPLY button to change the
parameter and return to the Parameter List Screen. If no further
changes are necessary, press the BACK button to return to the
Parameter List Screen. Once all the necessary adjustments
have been made, press the BACK button to return to the Setup
Screen. Repeat this procedure to adjust the parameters in other
screens.
Press the SAVE button to program all changes made to the
control parameters and return to the Status Screen. Leaving the
Setup Screen without pressing the SAVE button will erase the
changes made to the control parameters and revert them back
to their previous settings.
• Pumps - Allows access to change pump delay timing.
• BMS - Allows access to change the 0 - 10Vdc BMS
parameters.
To change a parameter, press one of the seven screen buttons.
A list of parameters and their corresponding location are
located on pages 11 and 12, Table 1B. Once a Screen button
is pressed a list of adjustable parameters will appear.
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 on page 24 for information regarding
adjusting the date and time.
Select the parameter to be adjusted by pressing the SELECT Main button - Pressing this button brings up the Main Screen.
button next to the parameter. The first time the parameters From this screen navigation to eight (8) other screens is
are accessed, you will be required to enter the service possible. Reference the Main Screen section on page 17 of this
password. The service password is 5309. Using the keypad, manual for more information regarding this screen.
enter the password and then press the OK button. If the
Save button - Pressing this button will save all changes made to
password is not entered correctly, the screen will revert to the
the control parameters.
Parameter List Screen and you will not be able to adjust the
Status button - Pressing this button displays the Status Screen.
This screen shows the current status of the SYNC boiler.
Reference pages 13 - 14 for more information regarding this
screen.
parameters. If a digit has been entered incorrectly, press the
left arrow key on the keypad to back the digit up.
18
Service Manual
1 Service
(continued)
Service/Setup Parameters Screen:
The Service / Setup Screen allows access to 10 parameters. If either BMS configuration is selected, additional parameters
Those parameters are as follows:
for BMS operation will have to be adjusted. Reference
the BMS parameters on pages 27 and 28 for information
regarding adjusting these parameters. There are three (3) other
configuration selections that are possible, however, they must
NOT be used on the SYNC boiler.
This parameter can only be changed by the installer. The default
configuration is Cascade Set Point Thermostat based.
• Service Notification Time - When the boiler determines
that a scheduled service is due based on days of
installation, the Service Needed screen will appear. This
parameter can only be changed by the installer. The
adjustment range for this parameter is 0 months to 36
months. The default time is 12 months.
• Service Notification Running Hours - When the boiler
determines that a scheduled service is due based on the
hours of actual operation. This parameter can only be
changed by the installer. The adjustment range for this
parameter is 0 hours to 100,000 hours. The default time is
10,000 hours.
• Demand Configuration - Sets the configuration of the
control modules inside the boiler. The configuration
selections are:
Demand Configuration 1: Cascade Set Point Thermostat
based - the control modulates the boiler based on the user
set point and the temperature of the controlling sensor. An
enable signal from a remote end switch or enabling device
must be present to initiate a system heat call.
Demand Configuration 4: Cascade Set Point Modbus
Thermostat based - the control modulates the boiler based
on the user set point and the temperature of the controlling
sensor. An enable signal is provided by writing to the
holding registers on the Modbus communication board.
Demand Configuration 2: Cascade BMS Thermostat
based - a 0 - 10Vdc signal is provided to the boiler to
control either the set point or the modulation of the boiler.
An enable signal from a remote end switch or enabling
device must be present to initiate a system heat call.
• Service Notification Cycles - When the boiler determines
that a scheduled service is due based on the number of
boiler cycles, the Service Needed screen will appear. This
parameter can only be changed by the installer. The range
for this parameter is 0 cycles to 100,000 cycles. The default
is 10,000 cycles.
Demand Configuration 5:
Cascade Modbus BMS
Thermostat based - a 0 - 10V dc signal is provided to the
boiler to control either the set point or the modulation of
the boiler. An enable signal and an equivalent 0 - 10V signal
is provided by writing to the holding registers on the
Modbus communication board.
• Ramp Delay - Sets the mode of operation of the ramp delay.
The selections are:
Demand Configuration 3: Cascade BMS Voltage based - a
0 - 10Vdc signal is provided to the boiler to control either
set point or modulation. A minimum voltage signal is
required to initiate a system heat call.
Demand Configuration 6: Cascade Modbus BMS Voltage
based - a 0 - 10V dc signal is provided to the boiler to
control either set point or modulation. An equivalent 0 -
10V dc signal is provided by writing to the holding registers
on the Modbus communication board.
0. Off - Ramp delay disabled.
1. Step Up - The total output of the boiler or cascade will
be limited after the call for heat begins.
2. Step Up / Down - The initial limitation will be
determined by how long the boiler or cascade has been
off. This parameter can only be changed by the
installer. The default value is 0 - Off.
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Reference page 18 for information regarding changing
parameters.
• Maximum Service Time - Service Mode allows the
installer to control the fan speed of the individual control
modules for the purposes of combustion analysis.
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 on page 24 for information regarding
adjusting the date and time.
Service Mode will override all other heat demands,
however, all safeties will remain intact. Maximum service
time sets the length of time the boiler will stay in Service
Mode if no buttons are pressed before reverting back to
its original state. This parameter can only be changed by
the installer. The time range of this parameter is 0 to 40
minutes. The default value is 20 minutes.
Back button - Pressing this button will back the screen up to
the previous screen.
• Temperature Units - The control can be configured to
display temperatures in either °C or °F. The default is °F.
• User Password - Allows the user to access and change a
limited number of control parameters. The access code
can be changed by the user or the installer to a code of
their choosing. The default code is 0704.
• LCD Backlight - Sets the length of time the LCD Screen
will stay on after a button has been pressed. This
parameter can be changed by the user or the installer.
The time range for this parameter is 30 seconds to ON.
With a setting of ON, the LCD Screen will be on
continuously. The default time is 15 minutes.
• LCD Brightness - Controls the brightness of the screen.
This parameter can be changed by the user or the
installer. The range for this parameter is 10% to 100%.
The default percentage is 50%.
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(continued)
Set Point Parameters Screen:
The Set Point Screen allows access to 12 parameters. Those
parameters are as follows:
The user or installer may not go below this
value when programming the “User Set Point”.
The
temperature range of this parameter is 0° to 190°F. The
default value is 60°F.
• User Set Point - Sets the water temperature set point for
fixed temperature operation or the maximum
temperature set point when the outdoor air sensor is
used. This parameter can be changed by the user or the
installer. The temperature range of this parameter is 50°
to 190°F. The default value is 125°F.
• Maximum User Set Point - Sets the maximum water
temperature set point that can be used for space heating.
The user or installer may not go above this value when
programming the “User Set Point”. The temperature
range of this parameter is 0° to 190°F. The default value
is 190°F.
• Hot Water Tank Set Point - When a tank sensor is
installed in a hot water storage tank, the hot water tank
set point sets the target temperature of the water in the
tank. This parameter can be changed by the user or the
installer. The temperature range of this parameter is 60°
to 185°F. The default value is 125°F.
• Drop in Inlet Temperature for Ending Anti-cycling - The
control will bypass the anti-cycling time if the inlet water
temperature drops too quickly. The control will use the
inlet water temperature at Heat Exchanger 1 when it shuts
off as the starting point. If the temperature drops below the
temperature parameter the control will abort anti-cycling
and allow the boiler to fire. This parameter can only be
changed by the installer. The temperature range of this
parameter is 0° to 86°F. The default value is 10°F.
• Anti-cycling Time - Once a system heat call has been
satisfied, a set amount of time must elapse before the
control will respond to a new system heat call. The
control will block the new system heat call and Anti-
cycling will be shown in the boiler status display until the
time has elapsed or the inlet water temperature drops
below the parameter drop in inlet temperature for ending
anti-cycling. This parameter can only be changed by the
installer. The time range for this parameter is 0 minutes
to 40 minutes. The default value is 1 minute.
• Hot Water Tank Differential - Sets how many degrees
below the Hot Water Tank Set Point the hot water tank
temperature must drop before the boiler will turn on.
This parameter can only be changed by the installer. The
temperature range for this parameter is 0° to 100°F. The
default value is 5°F.
• Indirect HW Set Point - When a Hot Water Generation
call for heat becomes active, the control will use the
Indirect HW set point to determine the firing rate of the
boiler based on the actual boiler outlet water
temperature. This parameter can be changed by the user
or the installer. The temperature range of this parameter
is 50° to 190°F. The default value is 180°F.
• Night Setback Set Point - Once the internal clock has
been set correctly, the night setback feature can be used to
program a lower water temperature set point for space
heating. This parameter can be changed by the user or
the installer. The temperature range for this parameter is
32° to 140°F. This feature is turned off with a setting of
32°F. The default value is 32°F.
Reference page 18 for information regarding changing
parameters.
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 on page 24 for information regarding
adjusting the date and time.
• Minimum User Set Point - Sets the minimum water
temperature set point that can be used for space heating
operation.
Back button - Pressing this button will back the screen up to the
previous screen.
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Outdoor Reset Parameters Screen:
• Outdoor Temperature at Low Reset Temperature - When
the outdoor air temperature rises to or above this point, the
water temperature will be at its minimum setting. This
parameter can only be changed by the installer. The
temperature range of this parameter is 25° to 86°F. The
default value is 70°F.
When the outdoor air sensor is installed, the control will
calculate the water temperature set point based on the
outdoor air temperature. As the outdoor air temperature
drops the water temperature set point increases. This feature
allows the boiler to be more efficient in periods of mild
weather.
• Outdoor Shutdown Set Point - When the outdoor air
temperature rises above this point, the control will block
all system heat calls. The Hot Water Generation call will
be unaffected. This parameter can be changed by the
user or the installer. The temperature range of this
parameter is 32° to 122°F. The default value is 70°F.
The Outdoor Reset Screen allows access to eight (8)
parameters. Those parameters are as follows:
• Reset Temperature at Low Outdoor Temperature - When
the outdoor air temperature drops to its minimum
setting, the water temperature will be at this point, if the
user set point parameter is set higher. This parameter can
only be changed by the installer. The temperature range
of this parameter is 0° to 190°F. The default value is
180°F.
• Outdoor Shutdown Differential - The number of degrees
below the outdoor shutdown set point that the outdoor air
temperature must go before the boiler will respond to a
system heat call. This parameter can be changed by the user
or the installer. The temperature range of this parameter is
0° to 90°F. The default value is 10°F.
• Reset Temperature at High Outdoor Temperature -
When the outdoor air temperature rises to or above its
maximum setting, the water temperature will be at this
point. This parameter can only be changed by the
installer. The temperature range of this parameter is 32°
to 180°F. The default value is 100°F.
• Boost Time - If the boost increment parameter is set to
active, the boost time parameter will set the amount of time
that must elapse with a system heat call before the water
temperature set point will be increased. This parameter can
be changed by the user or the installer. The time range for
this parameter is 0 minutes to 250 minutes. The default
value is 20 minutes.
• Outdoor Temperature at High Reset Temperature -
When the outdoor air temperature drops to this point,
the water temperature will be at its maximum setting.
However, if the user set point is set lower, the water
temperature will be limited by the user set point. This
parameter can only be changed by the installer. The
temperature rane of this parameter is -22° to 70°F. The
default value is 25°F.
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(continued)
• Boost Increment - If a system heat call last longer than the
programmed boost time setting and there have been no Hot
Water Generation calls, the control will increase the water
temperature set point by the amount in this parameter. If
the system heat call continues through another time period,
the set point will be increased again. This will continue
until either the system heat call ends, a maximum of 20
increases has occurred, or the maximum set point has been
reached. Once the system heat call has been satisfied the set
point will revert back to its calculated setting. This
parameter can be changed by the user or the installer. The
temperature range of this parameter is 0° to 45°F. The
default value is 0°F. This feature will be active if this
parameter is set to anything other than 0°F.
Reference page 18 for information regarding changing
parameters.
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 on page 24 for information
regarding adjusting the date and time.
Back button - Pressing this button will back the screen up to
the previous screen.
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Night Setback Parameters Screen:
The Night Setback Screen allows access to 15 parameters. Example: Monday ON: 22:30, Tuesday OFF: 6:45. If you wish
Those parameters are as follows:
to skip a day and no night setback is necessary, program the on
and off times the same and set them prior to 12:00 (noon). If
you wish to keep night setback active throughout an entire day,
program the on and off times the same and set them after 12:00
(noon). The default times for each day will be on at 18:00 and
off at 8:00.
• Date and Time - The control uses an internal clock for the
night setback feature and for logging of events. For these
features to work correctly, the clock must be set when the
boiler is first installed or any time the boiler has been
powered off for more than 30 days.
To adjust the on and off times, select the parameter to be
adjusted by pressing the SELECT button next to the parameter.
Using the keypad, adjust the time by working from left to right.
If a digit has been entered incorrectly, press the left arrow key
on the keypad to back the digit up. If no change is necessary,
press the BACK button to return to the Parameter List Screen.
Once the correct time has been entered press the OK button on
the display to program the time into memory and return to the
Parameter List Screen.
To set the clock, press the SELECT button in the upper right-
hand corner of the display. The date and time are displayed
as “Day dd/mm/yy hh:mm”. Day = day of the week (1 =
Monday, 2 = Tuesday, etc.), dd = date, mm = month, yy =
year, hh = hour, mm = minutes (24 hours time; 2:30 PM =
14:30). Using the keypad, adjust the date and time by working
from left to right. If a digit has been entered incorrectly, press
the left arrow key on the keypad to back the digit up. If a
change is not necessary, press the BACK button to return to
the Parameter List Screen. Once the correct date and time Reference page 21 for information regarding NSB Set Point
have been entered press the OK button on the display to Temp programming.
program the date and time into memory and return to the
Apply button - If changes have been made to the date and time
or to one of the on or off timers, the APPLY button must be
Parameter List Screen.
The internal clock does not adjust for Daylight Savings Time pressed to program the changes into the control module and
and therefore, will require a manual adjustment.
return to the Setup Screen.
• On Timer and Off Timer - If the parameter night setback Back button - Pressing this button will back the screen up to the
set point is set to anything other than 32°F, the night previous screen.
setback feature becomes active. This will require on and
off times to be programmed for the days that reduced
temperatures are required. Each day of the week
(Monday through Sunday) will have an on and off time.
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(continued)
Cascade Parameters Screen:
• Cascade Off/On Differential - Sets how many degrees
below the turn off temperature (set point + Cascade Off
Differential) the temperature has to go before the lead
boiler will turn on. This parameter can only be changed
by the installer. The temperature range of this parameter
is 0° to 72°F. The default value is 20°F.
Cascade Operation
When multiple boilers are installed, they can be wired
together in a cascade sequence. A maximum of eight (8)
boilers can be controlled from a single control. In this
application one boiler would be designated as the Leader and
all others would be designated as Members. The designated
Leader boiler determines the total output needed from the
group based on the set point and the system sensor reading.
Reference the Wiring of the Cascade section in the SYNC
Installation and Operation Manual for more information
regarding the cascade feature.
• Maximum Outlet Temperature - Sets the set point that
individual boilers will attempt to achieve in a cascade.
When a boiler is commanded to fire by the Leader, it will
attempt to achieve this temperature at its outlet. The Leader
will control the modulation of the last boiler to fire in order
to hold the temperature at the system supply sensor to the
user set point. If any of the boiler outlet temperatures reach
the Maximum Outlet Temperature setting, the boiler will
then modulate down on its own in order to keep its outlet
temperature within the Maximum Outlet Temperature
setting. Therefore, this parameter can be used to limit the
outlet temperatures of all the boilers in a cascade.
The Cascade Screen allows access to four (4) parameters.
Those parameters are as follows:
• Cascade Address - The boiler designated as the Leader
should be programmed with address 0-1. All Member
boilers require addresses from 2-3 through 14-15. The
address must be different for each member. The
addresses can be in any order, regardless of the order in
which the boilers are wired together. This parameter can
only be changed by the installer. The default address is
0-1.
Note that this parameter does not apply when the boiler is
in Hot Water Generation Mode. This parameter can be
changed by the user or the installer. The temperature range
of this parameter is 32° to 212°F. The default value is 185°F.
Reference page 18 for information regarding changing
parameters.
• Cascade Off Differential - Sets how many degrees above
set point the temperature has to go before the lead boiler
will shut off. This parameter can only be changed by the
installer. The temperature range of this parameter is 0° to
72°F. The default value is 10°F.
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 on page 24 for information regarding
adjusting the date and time.
Back button - Pressing this button will back the screen up to the
previous screen.
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Pumps Parameters Screen:
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 on page 24 for information regarding
adjusting the date and time.
The Pumps Screen allows access to four (4) parameters.
Those parameters are as follows:
• Boiler Pump Delay - Sets the length of time the boiler
pumps will run after a system heat call has been satisfied.
This parameter can only be changed by the installer. The
time range for this parameter is 0 minutes to 40 minutes.
The default time is 30 seconds.
Back button - Pressing this button will back the screen up to the
previous screen.
• HW Pump Delay - Sets the length of time the Hot Water
Generation pumps (if connected) will run after a Hot
Water Generation call has been satisfied. This parameter
can only be changed by the installer. The time range for
this parameter is 0 minutes to 40 minutes. The default
time is 30 seconds.
• System Pump Delay - Sets the length of time the system
pump (if connected) will run after a system heat call has
been satisfied. This parameter can only be changed by the
installer. The time range for this parameter is 0 minutes
to 40 minutes. the default time is 30 seconds.
• System Pump Mode - Sets the configuration of the system
pump. The configuration selections are:
0. The system pump will be on continuously except
during outdoor shutdown.
1. The system pump will be off.
2. The system pump will be on only during a system
heat call.
This parameter can only be changed by the installer. The
default configuration is 2: On only during a system heat call.
Reference page 18 for information regarding changing
parameters.
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(continued)
0 - 10Vdc BMS Parameters Screen:
ModBus Timeout
0-10Vdc Operation
• BMS Voltage at Minimum Set Point - Determines the
voltage at which the external signal begins to increase the
set point. Below this voltage, the set point will be at the
setting of the BMS Set Point Minimum Voltage
parameter. This parameter is only active when the BMS
Type is set to Set Point. This parameter can only be
changed by the installer. The range of this parameter is 0
to 10V. The default value is 2V.
When the Demand Configuration parameter (see page 19)
is set to either Cascade BMS Thermostat Based, Cascade
BMS Voltage Based, Cascade Modbus BMS Thermostat
Based, or Cascade Modbus BMS Voltage Based; a 0 - 10Vdc
signal can be supplied to the terminal strip connection or
through Modbus communications to control a single unit or
a multiple unit cascade.
The BMS Screen allows access to 11 parameters. Those
parameters are:
• BMS Voltage at Maximum Set Point - Determines the
voltage at which the external signal forces the set point to
the setting of the BMS Set Point Maximum Voltage
parameter. This parameter is only active when the BMS
Type is set to Set Point. This parameter can only be changed
by the installer. The range of this parameter is 2V to 10V.
The default value is 10V.
• BMS Type - When the unit or cascade is controlled by the
0-10Vdc BMS input, the voltage signal can control either
the modulation rate or set point. This parameter can only
be changed by the installer. The default method of
control is modulation rate.
• BMS Set Point at Minimum Voltage - Determines the set
point used by the unit or cascade when the BMS voltage
is at or below the setting of the BMS Voltage Minimum
Set Point parameter. This parameter is only active when
the BMS Type is set to Set Point. This parameter can only
be changed by the installer. The temperature range of this
parameter is 32° to 179°F. The default value is 70°F.
• BMS Voltage at Start Call for Heat - When the Demand
Configuration parameter (see page 19) is set to Cascade
BMS Voltage Based, this parameter determines the BMS
input voltage at which the unit or cascade is enabled. The
unit or cascade will become enabled when the BMS input
voltage rises up to or above this value. This parameter can
only be changed by the installer. The range of this
parameter is 0 to 10V. The default value is 2V.
• BMS Set Point at Maximum Voltage - Determines the set
point used by the unit or cascade when the BMS voltage
is at or above the setting of the BMS Voltage Maximum
Set Point parameter. This parameter is only active when
the BMS Type is set to Set Point. This parameter can only
be changed by the installer. The temperature range of this
parameter is 70° to 190°F. The default value is 179°F.
• Drop in BMS Voltage to End Call for Heat - When the
Demand Configuration parameter (see page 19) is set to
Cascade BMS Voltage Based, this parameter determines the
BMS input voltage at which the unit or cascade is disabled.
The unit or cascade will become disabled when the BMS
input voltage drops down to or below the BMS voltage at
start call for heat minus this value. This parameter can only
be changed by the installer. The range of this parameter is
0 to 10V. The default value is 1V.
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ModBus Timeout
Reference page 18 for information regarding changing
parameters.
• BMS Modulation at Minimum Voltage - Determines the
modulation rate of the unit or cascade when the BMS
input voltage is at or below the setting of the BMS Voltage
at Minimum Modulation parameter. This parameter is
only active when the BMS Type is set to modulation rate.
This parameter can only be changed by the installer. The
range of this parameter is 0% to 100%. The default value
is 14.5%.
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 on page 24 for information regarding
adjusting the date and time.
Back button - Pressing this button will back the screen up to the
previous screen.
• BMS Modulation at Maximum Voltage - Determines the
modulation rate of the unit or cascade when the BMS
input voltage is at or above the setting of the BMS Voltage
at Maximum Modulation parameter. This parameter is
only active when the BMS Type is set to modulation rate.
This parameter can only be changed by the installer. The
range of this parameter is 14.5% to 100%. The default
value is 100%.
• BMS Voltage at Minimum Modulation - Determines the
voltage at which the external signal begins to increase the
modulation rate (power). Below this voltage, the
modulation rate (power) will be at the setting of the BMS
Modulation at Minimum Voltage parameter. This
parameter is only active when the BMS Type is set to
modulation rate (power). This parameter can only be
changed by the installer. The range of this parameter is
0V to 10V. The default value is 2V.
• BMS Voltage at Maximum Modulation - Determines the
voltage at which the external signal forces the modulation
rate (power) to the setting of the BMS Modulation at
Maximum Voltage parameter. This parameter is only
active when the BMS Type is set to modulation rate
(power). This parameter can only be changed by the
installer. The range of this parameter is 2V to 10V. The
default value is 10V.
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(continued)
Cascade Screen:
System Temperature - This is the water temperature as measured
by the system sensor located in the system supply piping.
The Cascade Screen provides the status of the cascade system.
Items that can be viewed on the Cascade Screen are as follows:
SH Set Point - This is the set point of the cascade system.
The boiler designated as the Leader will use this set point
to determine the power level required to bring the system
temperature to this point. A default value of 50°F (10°C) is
displayed when the SH Call for Heat is inactive.
Boiler Power Level Indicators - For each boiler present in
the cascade a power level indicator will be present above
its corresponding number.
The level will rise and
fall indicating the approximate power level of the boiler.
The display box underneath each number will
display “HW” when that boiler is providing heat for a Hot
Water Generation call.
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 on page 24 for information regarding
adjusting the date and time.
On Timer and Off Timer - The ON and OFF timers are
used to force each boiler in the cascade to have a
minimum on and off time to prevent short cycling.
Status button - Pressing this button displays the Status Screen.
This screens shows the current status of the SYNC boiler.
Reference the Status Screen on page 13 for more information
regarding this screen.
Block Switch On Timer
-
Whenever
a
boiler is
commanded to start, the block switch on timer is started.
This provides a delay between the first ignition system
and the second ignition system inside the boiler. Once the
second ignition system is started, the timer is reset and the
next boiler is prevented from starting until the timer
times out. This process is repeated for each boiler in the
cascade.
Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 17 for more
information regarding this screen.
Demand - Shows the status of the cascade. Displayed
items are:
No Demand - the Cascade leader has not received a
system heat call.
SH Demand - the Cascade leader has received a
system heat call.
Set Point Met - the system temperature has met the
User Set Point + the Off Differential.
Pump Delay - the cascade has satisfied a system
heat call and the system pump is running for a fixed
time.
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1
On
34
80
55
The Building Screen displays information that is specific to the Building Automation System and is being transmitted through
the Modbus communication link:
Modbus Address - This is the address of a specific SYNC
boiler. This address is set by dip switches on the Modbus
communication board. The value displayed here should
be the same as the value of the dip switches. The Building
Automation System should use this address to communicate
with the boiler.
Boiler Command - This displays the value written to register
40003 of the Modbus communication board by the Building
Automation System. The value is displayed as the percent of
firing rate, 80 = 80% firing rate.
Effective Setpoint - This displays the value written to register
40003 of the Modbus communication board by the Building
Automation System. The value is displayed as the effective
setpoint in degrees (°F or °C).
Boiler Enable - This displays the enable status that has been
transmitted to the boiler by the Building Automation System.
Boiler State - This displays the state code of the boiler. Please
reference the SYNC Modbus Instruction Manual for a full
definition of each code.
Note: The boiler can be configured to operate off the boiler
command or the effective setpoint. The boiler configuration
determines which value is meaningful.
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(continued)
Temps Screen:
The Temps Screen displays the various temperatures as
measured by sensors connected to each control module.
Items that can be viewed on the Temps Screen are as follows:
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 on page 24 for information regarding
adjusting the date and time.
• Heat Exchanger 1/2 Inlet - This is the water temperature
as measured by the sensor located in the inlet of each heat
exchanger.
Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the SYNC boiler.
Reference page 13 for more information regarding this screen.
• Heat Exchanger 1/2 Outlet - This is the water temperature
as measured by the sensor located in the outlet of each
heat exchanger.
Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 17 for more
information regarding this screen.
• Heat Exchanger 1/2 Flue - This is the temperature as
measured by the sensor located in the flue connection on
each heat exchanger.
• Set Point - Two temperatures are shown in this display.
the top temperature is the Cascade Maximum Outlet
Temperature. The lower temperature is the tank set point
for a Hot Water Generation call.
• System Sensor - This is the water temperature as
measured by the sensor located in the system supply
piping. The system sensor must be installed for the
proper operation of the boiler.
• Outdoor Sensor - This is the temperature of the outside
air as measured by the sensor located outside. The use of
the outdoor sensor is optional. If the sensor is connected
the control will calculate the set point based on the
programmed outdoor parameters. See page 22 for
information regarding adjusting the outdoor parameters.
If the sensor is not present, none will be shown in the
display.
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Burners Screen:
This screen provides the status of the combustion air blowers
and flame signals. Items that can be viewed on the Burners
Screen are as follows:
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 on page 24 for information regarding
adjusting the date and time.
• Blower Power Level Indicator - Two (2) blowers are
depicted on the display. The top blower corresponds with
Heat Exchanger 1 or Top heat exchanger. The lower
blower corresponds with Heat Exchanger 2 or Bottom
heat exchanger. Beside each blower is a power level
indicator. The level will increase and decrease indicating
the approximate power level of the blower. The display
box underneath each indicator level will display the firing
rate of each control module.
Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the SYNC boiler.
Reference page 13 for more information regarding this screen.
Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 17 for more
information regarding this screen.
• RPM’s - Each blower will display the rpm that the
control module is requiring of the blower.
• Flame Signal - The flame signal for each control module
will be displayed in dc microamps.
32
Service Manual
1 Service
(continued)
Graph Select Screen:
The Graphs Screen consists of two (2) different screens. The
first screen is the Parameter Selection Screen. By pressing the
box beside the desired item, a check will appear in the selected
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 on page 24 for information regarding
adjusting the date and time.
box and the control will graph the status of that item.
maximum of five (5) items can be graphed at one time.
A
Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the SYNC boiler.
Reference page 13 for more information regarding this screen.
The second screen is accessed by pressing the NEXT button.
Once the items to be graphed are selected, press the NEXT
button to view the graph. Each item graphed will have a
different color line to represent it. The items selected will
be shown in a display bar with their Min and Max ranges
listed below them. Press the BACK button to return to the
Parameter Selection Screen.
Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 17 for more
information regarding this screen.
33
Service Manual
1 Service
History Screen:
The History Screen shows the status of various counters
and faults for each control module. Selection of the control
module to be viewed is accomplished by pressing the SELECT
button. The control module being displayed is shown in the
module box. Items that can be viewed on the History Screen
are as follows:
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 on page 24 for information regarding
adjusting the date and time.
Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the SYNC boiler.
Reference page 13 for more information regarding this screen.
• Power Hours - Shows the number of hours the control
has been powered on.
Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 17 for more
information regarding this screen.
• Successful Ignitions - Shows the number of times the
control has successfully ignited.
• Hours SH < 50% - Shows the number of hours the
control has operated at less than 50%.
• Total Ignitions - Shows the total number of times the
control has attempted to ignite.
• Last 10 Faults - Shows the last 10 faults of the control
module by date and time.
34
Service Manual
1 Service
(continued)
Service Mode Screen:
The Service Mode Screen allows the individual control
modules to override all other heat demands and operate at
a full fire condition for the purpose of combustion analysis.
Selection of the control module to be placed into Service
Mode is accomplished by pressing the SELECT button. The
control module being placed into Service Mode is shown in
the module box.
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 on page 24 for information regarding
adjusting the date and time.
Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the SYNC boiler.
Reference page 13 for more information regarding this screen.
To place the unit into Service Mode, press the ON/OFF button
until ON is displayed. The control module will override all
other heat demands, however, all safeties will be active. If no
buttons are pressed, the control module will automatically
revert back to its original state after the Max Service Time
delay has expired. The default setting for the Max Service
Time is 20 minutes. To take the control module out of Service
Mode, press the ON/OFF button until OFF is displayed.
Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 17 for more
information regarding this screen.
Items that can be viewed and interacted with on the Service
Mode Screen are as follows:
• Blower Power Level Indicator - A blower is depicted on
the display with a power level indicator beside it. The
level will increase and decrease indicating the
approximate power level of the blower. The display box
underneath the indicator level will display the firing rate
of the control module.
• RPM’s - The blower motor rpm that the control module
is requiring of the blower.
• Plus and Minus Buttons - By pressing the plus or minus
button the rpm of the blower motor can be increased or
decreased.
• Flame Signal - The flame signal for the control module
will be displayed in dc microamps.
35
Service Manual
2 Maintenance
Maintenance and annual startup
Table 2A Service and Maintenance Schedules
Owner maintenance
Service technician
(see the SYNC User’s Information Manual for
instructions)
(see the following pages for instructions)
General:
• Address reported problems
• Check boiler area
• Inspect interior; clean and vacuum if
necessary;
Daily
•Check pressure/temperature
gauge
• Clean condensate trap and fill with fresh
water
• Check for leaks (water, gas, flue,
condensate)
• Verify flue and air lines in good condition
and sealed tight
• Check vent piping
• Check air piping
• Check system water pressure/system
piping/expansion tank
• Check air and vent termination
screens
Monthly
• Check control settings
• Check ignition and flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check relief valve
• Check condensate drain system
• Check wiring and connections
•
Check
automatic
air
vents
•
Perform start-up checkout and
performance verification per Section 9
in the SYNC Installation and
Operation Manual.
• Test low water cutoff
• Reset button (low water cutoff)
Every
• Flame inspection (stable, uniform)
6 months
• Check boiler piping (gas and
water) for leaks
• 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.
• Operate relief valve
• Test low water flow conditions.
If combustion or performance
indicate need:
End
of season
months
•Shut boiler down (unless boiler
used for hot water generation)
• Clean heat exchanger
• Remove and clean burner using
compressed air only
• Clean the blower wheel
36
Service Manual
2 Maintenance
(continued)
Follow the service and maintenance procedures given throughout this manual and in component literature
shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler
or system. Failure to follow the directions in this manual and component literature could result in severe
personal injury, death, or substantial property damage.
ƽ WARNING
The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance
and care of the boiler designated in Table 2A and explained on the following pages must be performed to
assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could
result in equipment failure.
ƽ WARNING
Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as
noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,
causing severe personal injury or death.
ƽ WARNING
Address reported problems
Figure 2-1 Condensate Trap
1. Inspect any problems reported by the owner and correct
before proceeding.
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
Inspect boiler area
RETAINING
SCREW
PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids.
CONDENSATE FROM
HEAT EXCHANGER
2. Verify that air intake area is free of any of the contaminants
listed in Section 1 of the SYNC Installation and Operation
Manual. If any of these are present in the boiler intake
air vicinity, they must be removed. If they cannot be
removed, reinstall the air and vent lines per this manual
and the SYNC Installation and Operation Manual.
TO FLOOR
DRAIN
Inspect boiler interior
1. Remove the front access cover and inspect the interior of
the boiler.
The condensate trap must be filled with
water during all times of boiler operation
to avoid flue gas emission from the
condensate drain line. Failure to fill the
trap could result in severe personal injury
or death.
ƽ WARNING
2. Vacuum any sediment from inside the boiler and
components. Remove any obstructions.
Clean condensate trap
Check all piping for leaks
1. Inspect the condensate drain line, condensate PVC
fittings, and condensate trap.
Eliminate all system or boiler leaks.
ƽ WARNING
Continual fresh makeup water will
reduce boiler life. Minerals can build
up in sections, reducing heat transfer,
overheating heat exchanger, and causing
heat exchanger failure. Leaking water may
also cause severe property damage.
2. Remove the PVC cap retaining screw from the PVC cap
(FIG. 2-1).
3. Remove the 2 inch PVC cap with the switch located at the
top of the trap (FIG. 2-1).
4. Remove any sediment in the trap.
1. Inspect all water and gas piping and verify to be leak free.
5. Fill with fresh water until the water begins to pour out of
the drain.
2. Look for signs of leaking lines and correct any problems
found.
6. Replace the cap. Press the cap onto the trap until the cap
makes contact with the drain.
3. Check gas line using the procedure found in Section 6 -
Gas Connections of the SYNC Installation and Operation
Manual.
7. Replace the retaining screw.
37
Service Manual
2 Maintenance
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 has not been affected by
corrosive water conditions and to ensure
that the valve and discharge line have not
been altered or tampered with illegally.
Certain naturally occurring conditions
may corrode the valve or its components
over time, rendering the valve inoperative.
Such conditions are not detectable unless
the valve and its components are physically
removed and inspected. This inspection
must only be conducted by a plumbing
contractor or authorized inspection
agency – not by the owner. Failure to
re-inspect the boiler relief valve as directed
could result in unsafe pressure buildup,
which can result in severe personal injury,
death, or substantial property damage.
Flue vent system and air piping
ƽ WARNING
1. Visually inspect the entire flue gas venting system and air
piping for blockage, deterioration or leakage. Repair any
joints that show signs of leakage. Verify that air inlet pipe
is connected and properly sealed.
2. Verify that boiler vent discharge and air intake are clean
and free of obstructions.
Failure to inspect for the above conditions
and have them repaired can result in
severe personal injury or death.
ƽ WARNING
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 psi (82.7 kPa)).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.
Following installation, the valve lever
must be operated AT LEAST ONCE
A YEAR to ensure that waterways are
ƽ WARNING
clear.
Certain naturally occurring
4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly press push valve to flush vent.
Replace caps. Make sure vents do not leak. Replace any
leaking vents.
mineral deposits may adhere to the valve,
rendering it inoperative. When manually
operating the lever, water will discharge
and precautions must be taken to avoid
contact with hot water and to avoid water
damage. Before operating lever, check
to see that a discharge line is connected
to this valve directing the flow of hot
water from the valve to a proper place of
disposal. Otherwise severe personal injury
may result. If no water flows, valve is
inoperative. Shut down the boiler until a
new relief valve has been installed.
Check expansion tank
1. Expansion tanks provide space for water to move in
and out as the heating system water expands due to
temperature increase or contracts as the water cools.
Tanks may be open, closed or diaphragm or bladder type.
See Section 6 - Hydronic Piping of the SYNC Installation
and Operation Manual for suggested best location of
expansion tanks and air eliminators.
2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief
valve. Ensure that the reason for relief valve weeping is
the valve and not over-pressurization of the system due
to expansion tank waterlogging or undersizing.
Check boiler relief valve
1. Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is piped
with its discharge in a safe area to avoid severe scald
potential. Read Section 6 - Hydronic Piping of the SYNC
Installation and Operation Manual before proceeding
further.
38
Service Manual
2 Maintenance
(continued)
Inspect ignition and flame sense Check burner flame
electrodes
1. Inspect flame through observation window.
1. Remove the ignition and flame sense electrodes from the
boiler heat exchanger access cover.
2. If the flame is unsatisfactory at either high fire or low fire,
turn off boiler and allow boiler to cool down. Remove the
burner and clean it thoroughly using a vacuum cleaner or
compressed air. Do not use compressed air to clean burner
if performed inside a building.
2. Remove any deposits accumulated on the ignition/flame
sense electrode using sandpaper. If the electrodes cannot
be cleaned satisfactorily, replace with new ones.
3. Remove the burner, reference FIG. 2-2.
3. Replace ignition/flame sense electrode, making sure
gasket is in good condition and correctly positioned.
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 2-2).
Check ignition ground wiring
Figure 2-2 Burner Assembly
1. Inspect boiler ground wire from the heat exchanger
access cover to ground terminal strip.
DOOR FIBER
2. Verify all wiring is in good condition and securely
attached.
BURNER DOOR
BURNER DOOR
HEX NUT (6)
BURNER
3. Check ground continuity of wiring using continuity
meter.
AIR/GAS GASKET
4. Replace ground wires if ground continuity is not
satisfactory.
IGNITER GASKET
FLAPPER VALVE
SCREW (5X)
IGNITER
FLAME SENSE
GASKET
IGNITER SCREW (2X)
FLAPPER VALVE
FLAME SENSE
FLAME SENSE
SCREW (2X)
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good
condition and securely attached.
Check control settings
1. Go to the Setup Screen and check all settings. See Section
1 of this manual. Adjust settings if necessary. See Section
1 of this manual for adjustment procedures.
2. Check settings of external limit controls (if any) and
adjust if necessary.
Perform start-up and checks
1. Start boiler and perform checks and tests specified
in Section 9 - Start-up of the SYNC Installation and
Operation Manual.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
39
Service Manual
2 Maintenance
(continued)
5. Remove the condensate hose from the heat exchanger end.
Connect a field supplied 3/4” diameter hose to a drain pan.
Using field supplied means, cover the refractory in the back
of the combustion chamber of the heat exchanger.
Check flame signal
1. At high fire the flame signal shown on the display should
be at least 10 microamps.
6. Use a vacuum cleaner to remove any accumulation on the
boiler heating surfaces. Do not use any solvent.
2. A lower flame signal may indicate a fouled or damaged
flame sense electrode. If cleaning the flame sense
electrode does not improve, ground wiring is in good
condition, and ground continuity is satisfactory, replace
the flame sense electrode.
7. Brush the heat exchanger 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 pressure water supply.
3. See Section 3 - Troubleshooting in this manual for other
procedures to deal with low flame signal.
9. Allow the heat exchanger to thoroughly dry.
10. Remove the field supplied rear refractory cover from the
back of the combustion chamber of the heat exchanger and
reassemble.
Review with owner
1. Review the SYNC User’s Information Manual with the
owner.
11. Close isolation valves on piping to isolate boiler from
system. Attach a hose to the boiler drain and flush boiler
thoroughly with clean water by using purging valves to
allow water to flow through the water make-up line to the
boiler.
2. Emphasize the need to perform the maintenance schedule
specified in the SYNC User’s Information Manual (and in
this manual as well).
12. Perform start-up and check-out procedures in the Check
Flame and Combustion Section of the SYNC Installation
and Operation Manual.
3. Remind the owner of the need to call a licensed contractor
should the boiler or system exhibit any unusual behavior.
13. Replace the access cover and restore boiler to operation.
4. Remind the owner to follow the proper shutdown
procedure and to schedule an annual start-up at the
beginning of the next heating season.
Table 2B Heat Exchanger Cleaning Kits
Model
Kit
Part
Component
Description
Cleaning boiler heat exchanger
Number Number Number
For recommended materials; including brush, appropriate
extension(s), refractory cover, and detailed instructions see
Table 2B - Heat Exchanger Cleaning Kits.
MSC20083* Nylon 4” Wheel Brush*
SB 1.0 - 1.5 KIT30064 MSC20085 1/4” x 12” Drill Extension
MSC20086 1/4” x 24” Drill Extension
1. Shut down boiler:
• Follow the “To Turn Off Gas to Appliance” instructions
for the boiler in the SYNC Installation and Operation
Manual.
• Do not drain the boiler unless it will be exposed to
freezing temperatures. If using freeze prevention fluid
in system, do not drain.
* Do NOT use a metal brush. Only use
ƽ CAUTION
the kit provided brush or an equivalent
replacement nylon brush.
2. Allow time for the boiler to cool to room temperature if
it has been firing.
3. Remove the nuts securing the heat exchanger access
cover to the heat exchanger and set aside.
4. Remove the heat exchanger access cover, burner, and
gas/air arm assembly.
The boiler contains ceramic fiber
ƽ WARNING
materials. Use care when handling these
materials per instructions on page 3 of
this manual. Failure to comply could
result in severe personal injury.
40
Service Manual
2 Maintenance
Test low water flow conditions
10. Restrict the isolation valve until both control modules have
shut down. If both control modules have been shut down,
the test was successful.
This test is to be carried out once the
NOTICE
SYNC boiler is completely piped in
11. Disconnect the jumper wire from the low voltage terminal
strip connected in step 3.
with adequate gas and water flow.
Once the test is completed, ensure
that the isolation valve is opened up to
allow full water flow.
12. If necessary, reset the demand configuration in the Service/
Setup Menu to the required operational mode.
NOTE: See Section 1 of this manual for complete details of
the SmartTouch controls.
Test procedure
13. Completely open the isolation valve on the outlet piping of
the boiler.
1. Set the SYNC to operate with the demand configuration
parameter set to 1 (Cascade Set Point Thermostat-
Based).
14. Resume operation.
NOTE: This lockout is a soft lockout. Once the ꢀ T has
decreased to an acceptable level and there is a call for heat,
the unit will fire again to meet the demand.
NOTE: This can be accomplished by selecting the
demand configuration parameter in the Service/Setup
Menu. See Section 1 of this manual for complete details
of the SmartTouch controls.
Figure 2-3 Low voltage terminal strip & enable contacts
2. Set the system setpoint to the max user setpoint. Max
user setpoint will allow the boiler to operate without
reaching this setpoint. The boiler will require a load
large enough to dissipate a large portion of the heat it is
generating.
LOW VOLTAGE CONNECTION BOARD
1
2
3
4
5
6
7
8
9
ALARM
CONTACTS
RUN TIME
CONTACTS
LOUVER
PROVING
MODULE 2
FLOW SWITCH
MODULE 1
3. Simulate a call for heat by placing a jumper wire across
the enable contacts on the low voltage terminal strip
located at the rear of the unit (FIG. 2-3).
10 FLOW SWITCH
11 TANK
12 THERMOSTAT
ENABLE
CONTACTS
13 R
14 W
ENABLE
LBL20052 REV
B
15 SHIELD GND
16 A
17 B
4. Allow the unit to progress through its normal diagnostics
and pre-purge programming.
18 SHIELD GND
19 (+)
10V INPUT
0
-
20 (-)
21 SYSTEM
22 SENSOR
23 OUT DOOR
24 SENSOR
25 TANK
5. Allow the unit to fire and operate until the temperatures
stabilize. This occurs when the inlet and outlet
temperatures are rising together and the Delta T (ꢀ T)
is maintained.
26 SENSOR
27 SHIELD GND
28 B
29 A
30 SHIELD GND
6. When the unit stabilizes, begin to slowly shut off the
isolation valve on the outlet piping of the boiler (see
FIG. 2-4). This will begin to restrict the flow and
simulate a low flow condition.
Figure 2-4 Adjust outlet isolation valve
7. While slowly shutting off the isolation valve, refer to
the Burner Screen to watch the behavior of the boiler.
On this screen, you will witness each individual control
module modulating its’ respective burner’s firing rate
while reacting to the rising ꢀ T.
ADJUST OUTLET
ISOLATION VALVE
ONLY
8. When the ꢀ T reaches 50˚F for an individual heat
exchanger, the control for the heat exchanger will
attempt to modulate the firing rate down to protect it
from low flow conditions.
9. When the ꢀ T reaches 60˚F for an individual heat
exchanger, the control module for the heat exchanger
will turn off the respective burner.
NOTE: The Temperature Menu will show the inlet and
outlet temperatures for each individual heat exchanger.
41
Service Manual
3 Troubleshooting
Alarm Screen:
Reset button - The RESET button must be pressed to reset an
alarm. Once the button is pressed, the Reset Confirmation
Screen appears. You are asked if you wish to reset the control
module. If so, press the YES button. If you do not wish to reset
the control module press the NO button. If neither button is
pressed within 20 seconds, the screen will return to the Alarm
Screen.
If a fault occurs which requires a Manual Reset, the unit
will go into a lockout condition and the Alarm Screen will
be activated. The screen will switch between a black or red
background every 5 seconds with the text “Alarm Unit Needs
Servicing” shown on the display.
A message box shows the alarm status of the two (2) control
modules. Mod1 is for Control Module 1 and Mod2 is for
Control Module 2. A description of the alarm will be beside
the control module with the fault. If a control module does
not have a fault, “No Alarm Present” will be in the text.
Once the condition has been corrected and the alarm is reset,
the Status Screen will be displayed.
It is possible for one control module to be in alarm while the
other continues to function. However, it will not be possible
to view any other screens until the control module is reset.
42
Service Manual
3 Troubleshooting
(continued)
Label all wires prior to disconnection
when servicing controls. Wiring errors can
cause improper and dangerous operation.
Always disconnect power to the boiler
before servicing. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
Figure 3-1 Control Module Fuses
ƽ WARNING
F3 - 1.25 AMP FUSE
MAIN BOARD
F4 - 3.15 AMP FUSE
BLOWER
Never jumper (bypass) any device except
for momentary testing as outlined in the
Troubleshooting chart. Severe personal
injury, death, or substantial property
damage can result.
F5 - 5 AMP FUSE
PUMPS
F2 - 3.15 AMP FUSE
24V SUPPLY
ƽ WARNING
Before troubleshooting:
1. Have the following items:
a. Voltmeter that can check 120 VAC, 24 VAC, and
12 VDC.
4. Remove the two (2) nuts on the control module cover.
5. Inspect fuses F2, F3, F4, and F5, see FIG 3-1.
b. Continuity checker.
c. Contact thermometer.
2. Check for 120 VAC (minimum 102 VAC to maximum
132 VAC) to boiler.
6. The boiler is shipped with six (6) spare fuses in a plastic
bag located under the low water cutoff on the control
module.
3. Make sure thermostat is calling for heat and contacts
(including appropriate zone controls) are closed. Check
for 24 VAC between thermostat wire nuts and ground.
7. If necessary, replace open fuse (F3 is 1.25 amps, F2 and F4
are 3.15 amps, and F5 is 5 amps).
4. Make sure all external limit controls are installed and
operating.
Note: Fuses F2 - F5 are all slow blow fuses.
Do not jumper fuse or replace with any
ƽ WARNING
Check the following:
1. Wire connectors to control module are securely plugged
in at the control module and originating control.
fuse except as specified. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
2. Gas pressures:
8. Re-install the control module cover using the nuts
removed in Step 4.
• Maximum: 14 inches w.c. (3.5 kPa) natural,
14 inches w.c. (3.2 kPa) LP with no flow (lockup)
or with boiler on
Note: If the spark wire was unplugged, reattach it to the
control.
• Minimum: 4 inches (5 inches on 1.0 models only) w.c.
(1.0 kPa) natural, 8 inches w.c. (2.0 kPa) LP with gas
flowing (verify during boiler startup)
9. Re-install the control panel using the two (2) screws
removed in Step 3. Re-install the front access cover after
fuse inspection.
10. Restore power to the boiler at the external line switch
and verify boiler operation (Section 9 - Start-up in the
SYNC Boiler Installation and Operation Manual) after
completing boiler service.
Check control module fuses
ALWAYS check control module fuses
NOTICE
before replacing control module or any
major components (blower, etc.). If one
of these fuses is blown, it can prevent the
control module or other components from
operating.
1. Turn OFF the power to the boiler at the external line
switch.
2. Remove the front access cover.
3. Remove the two (2) screws securing the control panel to
the unit to gain access to the control module.
43
Service Manual
3 Troubleshooting
Table 3A Troubleshooting Chart - No Display
FAULT
CAUSE
CORRECTIVE ACTION
- No 120 VAC supplied to unit.
• Check external line switch, fuse, or breaker.
• Check position of ON/OFF switch. Turn switch to the
ON position.
• Check 120 VAC through the ON/OFF switch.
• Check wiring harness connection between display
board and main control board. Connect
harness at both points.
No Display
- No voltage through the switch.
- Bad display board.
• Replace switch.
• Replace board.
- Bad main control board.
- Blown fuse.
• Replace the main control board.
• Replace fuse F3 on the main control board, see
page 43 of this manual.
- Main control board temperature set point • Review temperature setting.
satisfied.
- Remote thermostat satisfied.
• Review remote thermostat setting.
No Burner
Operation
- Outside air temperature above Warm • Check location of outside air sensor.
Check
Weather Shutdown (WWSD) set point for
main control board.
resistance of outdoor air sensor and compare to Table
3D on page 45 of this manual.
- Unit locked out on fault.
- Ramp delay active.
• Consult display for specific fault. Refer to fault
descriptions on page 47 of this manual for corrective
actions.
• Check ramp delay parameter settings. Optional PC
software required.
• Turn ramp delay feature off. See page 19 of this
manual for instructions on how to turn this feature off.
Unit Does
Not Modulate
Above 50%
• Check BMS parameter settings.
software required.
Optional PC
- Boiler controlled by BMS.
- Flue sensor open.
• Verify that the flue sensor is located in the flue outlet.
• Check wiring connections at the flue sensor.
• Check the resistance of the flue sensor and compare
to Table 3C on page 45 of this manual.
44
Service Manual
3 Troubleshooting
(continued)
Checking temperature sensors
The boiler temperature sensors (inlet water, outlet water, system water, flue, and outdoor air) are all resistance type devices. The
following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the
sensor at a known temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor.
Table 3B - Inlet/Outlet System Sensor Resistance vs. Temperature
Temperature
Resistance
Temperature
Resistance
50
68
18,780
12,263
8,194
5,592
3,893
2,760
158
176
194
212
--
1,990
1,458
1,084
817
--
86
104
122
140
--
--
Table 3C - Flue Temperature Sensor Resistance vs. Temperature
Temperature
Resistance
Temperature
Resistance
68
14,773
9,804
6,652
4,607
3,252
2,337
176
194
212
230
248
--
1,707
1,266
952
726
560
--
86
104
122
140
158
Table 3D - Outdoor Air Sensor Resistance vs. Temperature
Temperature
Resistance
Temperature
Resistance
-50
-40
-30
-20
10
490,813
336,606
234,196
165,180
118,018
85,362
20
30
40
50
60
70
80
46,218
34,558
26,099
19,900
15,311
11,883
9,299
0
10
62,465
45
Service Manual
3 Troubleshooting
Table 3E Troubleshooting Chart - Noisy System
FAULT
CAUSE
CORRECTIVE ACTION
- Supply gas problem. Natural gas pressures
should be between 4 inches w.c. (1.0 kPa)
and 14 inches w.c. (3.5 kPa). LP gas
pressures should be between 8 inches w.c.
(2.0 kPa) and 14 inches w.c. (3.2 kPa).
• Refer to Section 6 - Gas Connections of the SYNC
Installation and Operation Manual for detailed
information concerning the gas supply.
• Refer to the Gas Valve Adjustment Procedure on
page 55 of this manual for the proper gas valve setting.
Verify that the vent/air intake lengths do not exceed the
maximum listed in the General Venting section of the
SYNC Installation and Operation Manual.
- Gas/air mixture problem.
- Dirty/damaged burner.
Noisy
Operation
• Refer to page 39 in this manual for the burner removal
and inspection procedure. Clean or replace the burner
as necessary.
• Refer to Section
6
-
Hydronic Piping of the
SYNC Installation and Operation Manual for
- Low water flow through the heat exchanger. minimum flow rates. Verify that the boiler is piped in a
primary/secondary fashion and that the boiler and
system pump are running on a call for heat.
- Air in the piping system.
• Properly purge all air from the piping system.
• Verify system pressure is a minimum of 12 psi
(82.7 kPa).
- Low system water pressure.
• Replace fuse F5 on the control board, see page 43 of
this manual.
- Blown fuse.
No Pump
Operation -
Boiler Pump
System Pump
or
- Faulty pump.
• Replace pump.
- Internal fault on control board.
- Faulty pump relay.
• Replace main control board.
• Replace relay.
HW Pump
• Lower the system pressure below the 50 psi
(344.7 kPa) rating of the supplied relief valve or replace
Relief Valve
Opening
- System pressure exceeds relief valve the standard relief valve with a higher rated valve up to
setting.
the maximum pressure of the heat exchanger.
• Improperly sized expansion tank.
• Reset the pressure switches.
• Measure the supply gas pressure to determine cause
of failure. Natural gas pressures should be between
4 - 14 inches w.c. (1.0 - 3.5 kPa) and LP gas
pressures should be between 8 - 14 inches w.c.
(2.0 - 3.2 kPa).
Gas Pressure
Switch
(will require a
Either the manual reset low gas pressure
switch or the manual reset high gas pressure
switch tripped.
manual reset once
the condition has
been corrected.
Press the RESET
button on the
• Refer to Section 6 - Gas Connections of the SYNC
Installation and Operation Manual for detailed
information concerning the gas supply.
display to reset.)
• Correct the supply gas pressure if necessary.
• Check for a loose or misplaced jumper if pressure
switches are not installed.
46
Service Manual
3 Troubleshooting
(continued)
Table 3F Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
• Check boiler pump operation on a call for heat.
• Check for closed valves or obstructions in the boiler
piping.
Flow Switch/
LWCO
Either the low water cutoff or the optional
flow switch is not making.
• Verify system is full of water and all air has been
purged from the system.
(will require a manual
reset once condition has
been corrected. Press
the RESET button on
the display to reset.)
• Check for loose or misplaced jumpers if flow switch is
not installed.
• Replace fuse F2 on the control board, see page 43 of
this manual.
Blown fuse.
• Check condensate tube from unit to floor drain for
proper installation and obstructions.
Condensate
Drain Blocked
• Inspect condensate trap for blockage. Clean if
necessary.
(will require a manual The blocked drain switch has detected
excessive condensate build up inside the
unit.
reset once condition has
been corrected. Press
the RESET button on
the display to reset.)
• Check for loose wiring connection at wire harness
plug.
• Bad blocked drain switch. Replace switch.
Flame out of
Sequence
• Check supply voltage for proper polarity.
• Check external wiring for voltage feedback.
• Check the flame rod and make sure it is clean.
• Check the internal wiring for bad connections.
• Replace main control board.
(will require a manual
reset once the condition
has been corrected.
The flame detector circuit is seeing a flame
signal while no flame is present.
Press the RESET button
on the display to reset.)
Gas Valve /
Connection
• Check wiring harness connection at the gas valve and
at the main control board.
(will require a manual
reset once the condition
has been corrected.
The main control board did not detect the
gas valve.
• Replace the gas valve wire harness.
• Replace the gas valve.
Press the RESET button
on the display to reset.)
• Replace the main control board.
• Inspect spark electrode and associated wiring for
damage and connection. Reference page 39 of this
manual for removal and cleaning procedures.
Replace if necessary.
• Check for proper electrical grounding of the unit.
• Check incoming supply gas pressure. Natural gas
pressures should be between 4 - 14 inches w.c.
(1.0 - 3.5 kPa) and LP gas pressures should be
between 8 - 14 inches w.c. (2.0 - 3.2 kPa). Refer
to Section 6 - Gas Connections of the SYNC
Installation and Operation Manual for detailed
information concerning the gas supply.
Burner Did Not
Light
The unit has failed to prove main burner
ignition after one attempt. It will require a
manual reset before attempting to fire again.
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the display to reset.)
• Verify that the plastic hose from the gas valve to the
air inlet is connected and is not damaged.
• Verify that the vent/air intake pipes are correctly
installed and that there are no obstructions.
• Check for 24 VAC to the gas valve at the 2-pin
connection on the side of the main control board
during the ignition attempt. If no voltage is present,
replace the main control board.
47
Service Manual
3 Troubleshooting
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
• If 24 VAC is present at the main control board, check
the wiring between the main control board and the gas
valve. Replace the wiring if necessary. Do not
disconnect the wiring from the gas valve and attempt
to measure voltage at that point. The main control
board can detect if the gas valve is not connected and
will display the Gas Valve / Connection fault.
• If 24 VAC is present, check the outlet of the valve to
ensure the valve is flowing gas. With a manometer
connected to the outlet tap of the gas valve, when the
unit is in the prepurge period, there should be a
negative pressure present. When the valve is
energized a change in pressure should occur. If the
pressure change does not occur, the gas valve is not
opening. Replace the gas valve.
Burner Did Not
Light (cont’d)
The unit has failed to prove main burner
ignition after one attempt. It will require a
manual reset before attempting to fire again.
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the display to reset.)
• Inspect flame sensor and associated wiring.
Reference page 39 of this manual for removal and
cleaning procedures. Replace if necessary.
• Inspect the burner. Reference page 39 of this manual
for removal and cleaning procedures. Replace if
necessary.
• Replace the main control board.
• Inspect spark electrode and associated wiring for
damage and connection. Reference page 39 of this
manual for removal and cleaning procedures.
Replace if necessary.
• Check for proper electrical grounding of unit.
• Check incoming supply gas pressure. Natural gas
pressures should be between 4 - 14 inches w.c.
(1.0 - 3.5 kPa) and LP gas pressures should be
between 8 - 14 inches w.c. (2.0 - 3.2 kPa).
Refer to Section 6 - Gas Connections of the SYNC
Installation and Operation Manual for detailed
information concerning the gas supply.
Flame Lost
While Running
(will require a manual
reset once the condition
has been corrected.
The unit was running and lost the flame
signal. This condition occurred twice .
Press the RESET button
on the display to reset.)
• Verify that the plastic hose from the gas valve to the air
inlet is connected and is not damaged.
• Verify that the vent/air intake pipes are installed
correctly and there are no obstructions.
• Check for 24 VAC to the gas valve at the 2-pin
connection on the side of the main control board
during the ignition attempt. If no voltage is present,
replace the main control board.
48
Service Manual
3 Troubleshooting
(continued)
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
• If 24 VAC is present at the main control board, check
the wiring between the main control board and the gas
valve. Replace the wiring if necessary. Do not
disconnect the wiring from the gas valve and attempt
to measure voltage at that point. The main control
board can detect if the gas valve is not connected and
will display the Gas Valve / Connection fault.
Flame Lost
While Running
(cont’d)
• If 24 VAC is present, check the outlet of the valve to
ensure the valve is flowing gas. With a manometer
connected to the outlet tap of the gas valve, when the
unit is in the prepurge period, there should be a
negative pressure present. When the valve is
energized a change in pressure should occur. If the
pressure change does not occur, the gas valve is not
opening. Replace the gas valve.
The unit was running and lost the flame
signal. This condition occurred twice .
(will require a
manual reset once the
condition has been
corrected. Press the
RESET button on the
display to reset.)
• Inspect flame sensor and associated wiring.
Reference page 39 of this manual for removal and
cleaning procedures. Replace if necessary.
• Inspect the burner. Reference page 39 of this manual
for removal and cleaning procedures. Replace if
necessary.
• Replace the main control board.
• Verify that the system is full of water and that all air
has been properly purged from the system.
• Verify that the boiler is piped properly into the heating
system. Refer to Section 6 - Hydronic Piping of the
SYNC
Installation
and
Operation
Manual
for the proper piping methods for the SYNC.
• Check voltage to boiler pump motor on a call for
heat. If voltage is not present, check wiring back to
the pump relay.
Manual Reset
High Limit
• Replace the pump relay if necessary.
(will require a
• If 120 VAC is present on a call for heat and the boiler
pump is not operating, replace the pump.
manual reset once the
condition has been
corrected. Press the
RESET button on the
display to reset.)
The outlet water temperature has exceeded
the setting of the high limit.
• If the system pump is a variable speed pump, ensure
that the system flow is not less than the boiler flow.
• If operating on either an inlet or system supply
sensor, check temperature setting of the main control
board.
• If the high limit has tripped, check setting of the
device.
• Check resistance of water sensors and compare to
Table 3B on page 45 of this manual. Replace sensor
if necessary.
• Replace high limit.
49
Service Manual
3 Troubleshooting
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
Automatic Reset High Limit:
• Verify that the system is full of water and that all air
has been properly purged from the system.
• Verify that the boiler is piped properly into the heating
system. Refer to Section 6 - Hydronic Piping of the
SYNC Installation and Operation Manual
for the proper piping methods for the SYNC.
• Check voltage to boiler pump motor on a call for
heat. If voltage is not present, check wiring back to
the pump relay.
• Replace the pump relay if necessary.
• If 120 VAC is present on a call for heat and the boiler
pump is not operating, replace the pump.
Automatic Reset
High Limit / HEX-
Temp SW
• If the system pump is a variable speed pump, ensure
that the system flow is not less than the boiler flow.
• If operating on either an inlet or system supply
sensor, check temperature setting of the main control
board.
Either the auto-reset high limit (optional),
or the O-temp heat exchanger switch as
opened.
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
• If the high limit has tripped, check setting of the
device.
• Check resistance of water sensors and compare to
Table 3B on page 45 of this manual. Replace sensor
if necessary.
• Replace high limit.
HEX Temp SW:
• Check continuity across two contacts. Wires should
be connected at both poles of normally closed switch.
• Inspect the rear of the inner combustion chamber
at the burner level, for refractory breakdown/missing.
Replace the refractory if no damage to the heat
exchanger as a result of the burner, otherwise,
replace the heat exchanger.
• Faulty O-temp heat exchanger switch. Replace
switch.
• Vent/air intake lengths exceed the maximum allowed
lengths. Refer to Section 2 - General Venting of the
SYNC Installation and Operation Manual for
proper lengths.
The actual fan rpm is 30% lower than what
is being called for. Reference the Burners
Screen information on page 32 of this
manual.
Blower RPM’s
Too Low
• Check for obstruction or blockage in the vent/air
intake pipes or at terminations.
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
• Check the wiring connections at the fan and at the
main control board.
• Replace the fan.
• Replace the main control board.
• Replace fuse F4 on the control board, see page 43 of
this manual.
Blown fuse.
50
Service Manual
3 Troubleshooting
(continued)
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
• Vent/air intake lengths exceed the maximum allowed
lengths. Refer to Section 2 - General Venting of the
SYNC Installation and Operation Manual for
proper lengths.
Blower RPM’s
Too High
• Check for obstruction or blockage in the vent/air
intake pipes or at terminations.
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
The actual fan rpm is 30% higher than what
is being called for.
• Check the wiring connections at the fan and at the
main control board.
• Replace the fan.
• Replace the main control board.
• Check the sensors and their associated wiring.
Repair or replace the sensor or wiring if damaged.
Either the inlet water or outlet water • Measure the resistance of the sensors and compare
Sensor Open
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
temperature sensor has been disconnected.
the resistance to the tables on page 45 of this
manual.
• Replace the sensor if necessary.
• Check the sensors and their associated wiring.
Repair or replace the sensor or wiring if damaged.
Sensor Shorted
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
Either the inlet water or outlet water • Measure the resistance of the sensors and compare
temperature sensor has been shorted.
the resistance to the tables on page 45 of this
manual.
• Replace the sensor if necessary.
• Check the sensor and its associated wiring. Repair
or replace the sensor or wiring if damaged.
Flue Sensor
Open / Removed
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
• Measure the resistance of the sensors and compare
the resistance to the tables on page 45 of this
manual.
The flue sensor has been disconnected or
removed from the flue.
• Replace the sensor in flue.
• Replace the sensor if necessary.
• Check the sensor and its associated wiring. Repair
or replace the sensor or wiring if damaged.
Flue Sensor
Shorted
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
• Measure the resistance of the sensors and compare
the resistance to the tables on page 45 of this
manual.
The flue sensor has been shorted.
• Replace the sensor if necessary.
Louver Proving
Switch
• Check function of remote devices.
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
An optional remote proving switch is not
making.
• Check for loose or misplaced jumper if proving switch
is not installed.
Sensors equipped with an internal limit (such
as the Lochinvar Squire Indirect Tank), the
limit has opened due to temperature (195°F)
or the sensor has become disconnected.
• Check the tank temperature.
®
• Repair or replace the sensor wiring if damaged.
• Replace the sensor if necessary.
Tank Open
51
Service Manual
3 Troubleshooting
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
Air pressure switch contacts are open.
• Check the wiring connections to switch. Wires should
be connected to the common and normally closed
terminals.
• Vent/air intake lengths exceed the maximum allowed
lengths. Refer to Section 2 - General Venting of the
SYNC Installation and Operation Manual for
proper lengths.
• Check for obstruction or blockage in the vent/air
intake pipes or at terminations.
• Check reference hoses connected to the air pressure
switch for blockage or obstruction.
Air Flow Too
Low
• Inspect the burner. Reference page 39 of this manual
for removal and cleaning procedures. Replace if
necessary.
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the display to reset.)
• Inspect the heat exchanger. Reference page 40 of
this manual for removal and cleaning procedures.
Replace if necessary.
• Faulty air pressure switch. Replace switch.
• Check the wiring connections to the flap valve switch.
Replace or repair wiring if necessary.
• Check for obstruction in the vent / air intake pipes or
at terminations.
Flap valve contacts are in an open position.
• Verify combustion air blower is operating. Replace if
necessary.
• Replace flap valve switch.
• Check wiring connections to the flap valve switch.
Replace or repair wiring if necessary.
Flap Valve
Stuck Open
Flap valve contacts are in a closed position.
• Check flap valve for obstruction or blockage.
• Replace flap valve switch.
• Wait 15 minutes and try again.
Too Many
Resets - Try Later
Too many manual resets have occurred
during a 15 minute period.
• Turn power off to unit, wait 30 seconds and then turn
power back on.
• Check 120 VAC supply to the transformer.
• Check wiring connections at the low voltage terminal
strip.
Voltage Too
Low
120 VAC input to the main control board has
dropped below 80 VAC.
• Check the wire size/length to remote devices.
• Replace the main control board.
52
Service Manual
3 Troubleshooting
(continued)
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
The main control board has detected an
internal fault.
• Replace the main control board.
Internal Fault
Writing to
Memos
The main control board has detected an
internal fault.
• Replace the main control board.
• Replace the main control board.
The main control board has detected an
internal fault.
CRC Parameters
No Error Stored
The main control board has detected an • Press the RESET button on the SMART
internal fault.
TOUCH display panel.
• Inspect the heat exchanger. Reference page 40 of
this manual for the procedure on how to clean the
flue side of the heat exchanger.
• Inspect the flue sensor and associated wiring.
Measure the resistance of the flue sensor and
compare to Table 3C on page 45 of this manual.
Replace the sensor if necessary.
Flue Temp
Shutdown
The stack temperature has exceeded the
set parameters for the boiler.
• Verify that the vent/air intake pipes are properly
installed and that there are no obstructions.
• Replace the main control board.
• Verify that the system is full of water and that all air
has been properly purged from the system.
• Verify that the boiler is piped properly into the heating
system. Refer to Section 6 - Hydronic Piping of the
SYNC Installation and Operation Manual
for the proper piping methods for the SYNC boiler.
• Check for voltage to the boiler pump motor on a call
for heat. If voltage is not present, check the wiring
back to the pump relay. Replace the pump relay if
necessary.
Delta T
Shutdown
The temperature rise across the heat
exchanger has exceeded the set parameters
for the boiler.
• If 120 VAC is present on a call for heat and the boiler
pump is not operating, replace the pump.
• Verify that the boiler pump is set to the proper speed
or that the pump is the proper size. Reference
Section
6
-
Hydronic Piping of the SYNC
Boiler Installation and Operation Manual for boiler
pump specifications.
• Verify that the system is full of water and that all air
has been properly purged from the system.
• Verify that the boiler is piped properly into the heating
system. Refer to Section 6 - Hydronic Piping of the
SYNC Installation and Operation Manual
for the proper piping methods for the SYNC boiler.
Outlet Temp
Shutdown
Outlet water temperature has exceeded the
maximum outlet water temperature.
• Check for voltage to the boiler pump motor on a call
for heat. If voltage is not present, check wiring back
to the pump relay. Replace the pump relay if
necessary.
• If 120 VAC is present on a call for heat and the boiler
pump is not operating, replace the pump.
53
Service Manual
3 Troubleshooting
Combustion Analysis Procedure
Table 3H Flue Products
1. Turn the main power off to the boiler by placing the
“On/Off” switch in the OFF position.
Natural Gas
Propane
CO2 O2
2. Remove the flue temperature sensors from the flue pipe
connections. Note: Combustion measurements will be
made at this point.
CO2
O2
8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%
3. Turn the main power on to the boiler by placing the
“On/Off” switch in the ON position.
8. Once the Heat Exchanger 1 analysis is complete, test the
safety shutoff device by turning the manual shutoff valve
to the OFF position and ensuring that Heat Exchanger
1 shuts down and registers an alarm. Open the manual
shutoff valve, reset the control, and return to Service
Mode.
4. Navigate to the Service Mode Screen from the Status
Screen by pressing the MAIN button and then the
SERVICE MODE button.
5. On the Service Screen place Heat Exchanger 1 into
operation by selecting Heat Exchanger 1 with the SELECT
button and turning the heat exchanger on by pressing the
ON/OFF button (OFF indicates that the heat exchanger
is off and ON indicates that the heat exchanger should be
firing).
9. Repeat the same procedure for Heat Exchanger 2
by selecting Heat Exchanger 2 while on the Service
Mode Screen. Be certain to insert the probe from the
combustion analyzer into the Heat Exchanger 2 flue
temperature sensor location.
6. Insert the probe from a combustion analyzer into the
hole left by the removal of the flue temperature sensor.
10. Turn the main power off to the boiler and replace the
flue temperature sensor into the flue pipe connection.
Note: Heat Exchanger 1 is the top heat exchanger; please
11. Place the boiler back into normal operation.
ensure the probe is in the top flue sensor location.
You must replace the flue gas temperature
ƽ WARNING
7. Once the heat exchanger has modulated up to full fire
measure the combustion. The values should be in the
range listed in Table 3H above. CO levels should be
less than 200 ppm for a properly installed unit. If the
combustion is not within range reference the chart below
for possible causes and corrective actions.
sensor to prevent flue gas spillage into
the room. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
Table 3G Troubleshooting Chart - Combustion Levels
POSSIBLE CAUSE
CORRECTIVE ACTION
• Refer to Section 2 - General Venting of the SYNC Installation and Operation Manual
for the proper venting and air intake methods for the SYNC boiler.
Vent/Air Intake Length
or Obstruction
• Check for obstructions at the vent/air intake terminals.
• Refer to Section 6 - Gas Connections of the SYNC Installation and Operation
Manual for the proper gas supply for the SYNC boiler.
Gas Supply Pressure
• Refer to page 39 of this manual for burner removal and cleaning procedures.
• Replace burner if necessary.
Dirty/Damaged Burner
Gas Valve Adjustment
54
• Refer to page 55 of this manual for the gas valve adjustment procedure.
Service Manual
3 Troubleshooting
(continued)
Models 1.3 - 1.5
Gas valve adjustment procedure
If adjustment of the gas valve is deemed necessary, use the
following procedures: (Note: The procedures below are
model specific.)
Locate the throttle adjustment screw on top of the gas valve,
see FIG. 3-3. Using an Allen wrench, turn the screw a 1/4
turn counterclockwise to increase CO2 levels or a 1/4 turn
clockwise to decrease CO2 levels. After one adjustment on
the valve, follow the Combustion Analysis Procedure on page
54 of this manual to measure the combustion.
Under normal operating conditions this
CAUTION
valve should not need adjusting.
Model 1.0
If combustion is still not within the specified range, repeat
the procedure. This procedure SHOULD NOT be performed
more than four (4) times. If after four (4) adjustments and
the combustion is still not within the specified range, revisit
the possible causes in Table 3G on page 54 or replace the gas
valve.
Locate the throttle adjustment screw on top of the gas valve,
see FIG. 3-2. Using a screwdriver, turn the screw a 1/4 turn
counterclockwise to increase CO2 levels or a 1/4 turn
clockwise to decrease CO2 levels. After one adjustment on
the valve, follow the Combustion Analysis Procedure on
page 54 of this manual to measure the combustion.
Figure 3-3 Gas Valve Adjustment: Models 1.3 - 1.5
If combustion is still not within the specified range,
repeat the procedure. This procedure SHOULD NOT
be performed more than four (4) times. If after four (4)
adjustments and the combustion is still not within the
specified range, revisit the possible causes in Table 3G on
page 54 or replace the gas valve.
THROTTLE ADJUSTMENT
SCREW (REMOVE BLUE COVER)
Figure 3-2 Gas Valve Adjustment: Model 1.0
THROTTLE ADJUSTMENT SCREW
55
Revision Notes: Revision A (ECO #C02428) initial release.
Revision B (ECO #C03046) reflects changes made to the History,
Details, and Graphs screen shots (pgs. 15, 33 and 34).
Revision C (ECO #CO2918) reflects the addition of Tank Sensor Open
on page 50.
Revision D (ECO #C04062) reflects changes to the terminology in all
SYNC manuals and labels from module to heat exchanger (exception:
control module), edits made to the ceramic fiber material warning,
removal of the stabilitor from FIG. 2-2 (C04057) along with the addition
of the Low Water Flow Test Procedure (R02559).
Revision E (ECO #C04560) reflects the addition of Modbus to the
manual and a new heat exchanger cleaning procedure.
Revision F (ECO #C06388) reflects the correction of “Manual Reset
High Limit” instructions on page 15.
Revision G (ECO C07981) reflects the addition of the O-temp switch
(Table 3F) and edits made to the Inputs diagram on page 7.
Revision H (ECO C09659) reflects the update of information within
Section 3 “Troubleshooting” on page 43.
SYNC-SER Rev H
01/12
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