Lochinvar SYNO 15 User Manual

SYNC-USER Rev B  
User’s Information Manual  
Models: 1.0 - 1.3 - 1.5  
WARNING: If the information in these instructions is not  
followed exactly, a fire or explosion may result causing property  
damage, personal injury or death.  
-- Do not store or use gasoline or other flammable vapors and  
liquids in the vicinity of this or any other appliance.  
-- WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
• Do not touch any electrical switch; do not use any phone in your  
building.  
• Immediately call your gas supplier from a near by phone.  
Follow the gas supplier’s instructions.  
• If you cannot reach your gas supplier, call the fire department.  
-- Installation and service must be performed by a qualified  
installer, service agency, or the gas supplier.  
Save this manual for future reference.  
User’s Information Manual  
Please read before proceeding  
The SYNC Installation and Operation  
Boiler service and maintenance –  
NOTICE  
Manual along with the SYNC Service  
Manual are for use only by a qualified  
heating installer/service technician.  
Refer only to this User’s Information  
Manual for your reference. Improper  
installation, adjustment, alteration,  
service or maintenance can cause  
property damage, personal injury  
(exposure to hazardous materials) or  
loss of life. Installation and service must  
be performed by a qualified installer,  
service agency or the gas supplier (who  
must read and follow the supplied  
instruction before installing, servicing,  
or removing this boiler. This boiler  
contains materials that have been  
identified as carcinogenic, or possibly  
carcinogenic, to humans).  
To avoid electric shock, disconnect electrical supply  
before performing maintenance.  
To avoid severe burns, allow boiler to cool before  
performing maintenance.  
Boiler operation –  
• Do not block flow of combustion or ventilation air to  
the boiler. This boiler is equipped with a control which  
will automatically shut down the boiler should air or  
vent be blocked. If vent or air blockage is easily  
accessible and removable, remove it. The boiler should  
attempt to restart. If blockage is not obvious or cannot  
be removed, have the boiler and system checked by a  
qualified service technician.  
• Should overheating occur or gas supply fail to shut off,  
do not turn off or disconnect electrical supply to the  
circulator. Instead, shut off the gas supply at a location  
external to the appliance.  
When calling or writing about the boiler  
– Please have the boiler model and serial  
number from the boiler rating plate.  
NOTICE  
• 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.  
Consider piping and installation when  
determining boiler location.  
Any claims for damage or shortage in  
shipment must be filed immediately  
against the transportation company by  
the consignee.  
Boiler water –  
Thoroughly flush the system (without boiler  
connected) to remove sediment. The high-efficiency  
heat exchanger can be damaged by build-up or  
corrosion due to sediment.  
Factory warranty (shipped with unit)  
does not apply to units improperly  
installed or improperly operated.  
• 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.  
Failure to adhere to the guidelines on  
this page can result in severe personal  
injury, death, or substantial property  
damage.  
ƽ WARNING  
• Do not use “homemade cures” or “boiler patent  
medicines. Serious damage to the boiler, personnel,  
and/or property may result.  
• Continual fresh make-up water will reduce boiler life.  
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 or piping must be repaired at once to prevent  
makeup water.  
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
User’s Information Manual  
1 Prevent combustion air contamination  
If the boiler combustion air inlet is located  
ƽ WARNING  
Table 1A Corrosive Contaminants and Sources  
in any area likely to cause contamination,  
or if products which would contaminate  
the air cannot be removed, you must have  
the combustion air and vent re-piped and  
Products to avoid:  
Spray cans containing chloro/fluorocarbons  
Permanent wave solutions  
terminated  
to  
another  
location.  
Contaminated combustion air will  
damage the boiler, resulting in possible  
severe personal injury, death, or  
substantial property damage.  
Chlorinated waxes/cleaners  
Chlorine-based swimming pool chemicals  
Calcium chloride used for thawing  
Sodium chloride used for water softening  
Refrigerant leaks  
If the boiler combustion air inlet is  
located in a laundry room or pool facility,  
for example, these areas will always  
contain hazardous contaminants.  
ƽ WARNING  
Paint or varnish removers  
Pool and laundry products and common household and  
hobby products often contain fluorine or chlorine  
compounds. When these chemicals pass through the boiler,  
they can form strong acids. The acid can eat through the  
boiler wall, causing serious damage and presenting a possible  
threat of flue gas spillage or boiler water leakage into the  
building.  
Hydrochloric acid/muriatic acid  
Cements and glues  
Antistatic fabric softeners used in clothes dryers  
Chlorine-type bleaches, detergents, and cleaning solvents  
found in household laundry rooms  
Please read the information listed in Table 1A. If  
contaminating chemicals will be present near the location of  
the boiler combustion air inlet, have your installer pipe the  
boiler combustion air and vent to another location, per the  
SYNC Installation and Operation Manual.  
Adhesives used to fasten building products and other similar  
products  
Areas likely to have contaminants  
Dry cleaning/laundry areas and establishments  
Swimming pools  
To prevent the potential of severe personal  
ƽ WARNING  
injury or death, check for areas and  
products listed in Table 1A before  
installing the boiler or air inlet piping.  
Metal fabrication plants  
Beauty shops  
If contaminants are found, you MUST:  
• Remove products permanently.  
—OR—  
Refrigeration repair shops  
Photo processing plants  
• Relocate air inlet and vent  
terminations to other areas.  
Auto body shops  
Plastic manufacturing plants  
Furniture refinishing areas and establishments  
New building construction  
Remodeling areas  
Garages with workshops  
4
User’s Information Manual  
2 Maintenance schedule  
Service technician  
Owner maintenance  
(see the SYNC Service Manual)  
(see pages 6 - 8 for detailed instructions)  
General:  
• Address reported problems, if any  
• 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 control settings  
• Check air and vent termination  
screens  
• Check ignition and flame sense  
electrodes (sand off any deposits; clean  
and reposition)  
Monthly  
• Check relief valve  
• Check wiring and connections  
• Perform start-up checkout and  
performance verification per Section 9.  
• Check condensate drain system  
• Check automatic air vents  
• Flame inspection (stable, uniform)  
• Flame signal (at least 10 microamps at  
high fire)  
• Clean the heat exchanger if flue  
temperature is more than 54°F (30°C)  
above return water temperature.  
Test low water cutoff  
Every  
6 months  
Test low water flow conditions.  
• Reset button (low water cutoff)  
• Check boiler piping (gas and  
water) for leaks  
If combustion or performance  
indicate need:  
• Clean heat exchanger  
• Operate relief valve  
• Remove and clean burner using  
compressed air only  
• Clean the blower wheel  
End  
of season  
months  
Shut boiler down (unless boiler  
used for domestic hot water)  
Follow the maintenance procedures given throughout this manual. Failure to perform the service and  
maintenance or follow the directions in this manual could result in damage to the boiler or system, resulting  
in severe personal injury, death, or substantial property damage.  
ƽ WARNING  
5
User’s Information Manual  
2 Maintenance schedule  
Maintenance procedures  
Read the list of potential materials listed in Table 1A on  
page 4 of this manual. If any of these products are in the  
room from which the boiler takes its combustion air, they  
must be removed immediately or the boiler combustion  
air (and vent termination) must be relocated to another  
area.  
Boiler must be serviced and maintained  
The boiler must be inspected and started  
ƽ WARNING  
annually at the beginning of the heating  
season by a qualified service technician. In  
addition, the maintenance and care of the  
boiler designated on page 5 of this manual  
and explained on pages 6 through 8 must  
be performed to assure maximum boiler  
efficiency and reliability. Failure to service  
and maintain the boiler and system could  
result in equipment failure, causing  
possible severe personal injury, death, or  
substantial property damage.  
Check pressure/temperature gauge  
1. Make sure the pressure reading on the boiler pressure/  
temperature gauge does not exceed 24 psi (165.5 kPa).  
Higher pressure may indicate a problem with the  
expansion tank.  
2. Contact a qualified service technician if problem persists.  
Check vent piping  
1. Visually inspect the flue gas vent piping for any signs of  
blockage, leakage, or deterioration of the piping. Notify  
your qualified service technician at once if you find any  
problems.  
The following information provides  
NOTICE  
detailed instructions for completing the  
maintenance items listed in the  
maintenance schedule on page 5. In  
addition to this maintenance, the boiler  
must be serviced and started up at the  
beginning of each heating season by a  
qualified service technician.  
Failure to inspect the vent system as noted  
ƽ WARNING  
above and have it repaired by a qualified  
service technician can result in vent system  
failure, causing severe personal injury or  
death.  
Check boiler area  
Check air piping  
To prevent potential of severe personal  
ƽ WARNING  
injury, death, or substantial property  
1. Visually inspect the air inlet elbow to be sure it is  
unobstructed. Inspect the entire length of air piping to  
ensure piping is intact and all joints are properly sealed.  
damage, eliminate all materials discussed  
below from the boiler vicinity and the  
vicinity of the boiler combustion air inlet.  
If contaminants are found:  
2. Call your qualified service technician if you notice any  
problems.  
Remove products immediately from the  
area. If they have been there for an  
extended period, call a qualified service  
technician to inspect the boiler for  
possible damage from acid corrosion.  
Check relief valve  
1. Inspect the boiler relief valve and the relief valve  
discharge pipe for signs of weeping or leakage.  
If products cannot be removed,  
2. If the relief valve often weeps, the expansion tank may  
not be working properly. Immediately contact your  
qualified service technician to inspect the boiler and  
system.  
immediately call  
a
qualified service  
technician to re-pipe vent and air piping  
and locate vent termination/air intake  
away from contaminated areas.  
Check condensate drain system  
1. Combustible/flammable materials -- Do not store  
combustible materials, gasoline or any other flammable  
vapors or liquids near the boiler. Remove immediately if  
found.  
1. Inspect the condensate drain line, condensate PVC  
fittings and condensate trap.  
Fill condensate trap with water  
2. Air contaminants -- Products containing chlorine or  
fluorine, if allowed to contaminate the boiler intake air,  
will cause acidic condensate in the boiler. This will cause  
significant damage to the boiler if allowed to continue.  
1. Remove the PVC cap retaining screw from the PVC cap  
(FIG. 2-1).  
2. Remove the 2" PVC cap with the switch located at the top  
of the trap (FIG. 2-1).  
6
User’s Information Manual  
2 Maintenance schedule  
(continued)  
3. Fill with fresh water until the water begins to pour out  
of the drain.  
Use materials approved by the authority  
having jurisdiction. In the absence of  
other authority, PVC and CPVC pipe must  
comply with ASTM D1785 or D2845.  
Cement and primer must comply with  
ASME D2564 or F493. For Canada use  
CSA or ULC certified PVC or CPVC pipe,  
fittings, and cement.  
NOTICE  
NOTICE  
4. Replace the cap. Press the cap onto the trap until the  
cap makes contact with the drain.  
5. Replace the retaining screw.  
The condensate trap (FIG. 2-1) must be  
ƽ WARNING  
filled with water during all times of  
To allow for proper drainage on large  
horizontal runs, a second line vent may be  
required and tubing size may need to  
increase to 1 inch.  
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.  
The condensate line must remain  
unobstructed, allowing free flow of  
condensate. If condensate is allowed to  
freeze in the line or if the line is obstructed  
in any other manner, condensate can exit  
from the boiler tee, resulting in potential  
water damage to property. Call your  
qualified service technician to inspect  
the boiler and system.  
Figure 2-1 Condensate Trap  
2” PVC CAP WITH  
BLOCKED DRAIN SWITCH  
RETAINING  
SCREW  
PVC TEE ASSEMBLY  
(FACTORY SUPPLIED)  
CONDENSATE FROM  
HEAT EXCHANGER  
7. A condensate removal pump is required if the boiler is  
below the drain. When installing a condensate pump,  
select one approved for use with condensing boilers and  
furnaces. The pump should have an overflow switch to  
prevent property damage from condensate spillage. Call  
your qualified service technician to inspect  
the boiler and system.  
TO FLOOR  
DRAIN  
Condensate disposal  
1. This boiler is a high efficiency appliance that produces  
condensate.  
Figure 2-2 Condensate Disposal  
2. The rear of the boiler has a 1/2 inch (12.7 mm) PVC  
union for connection of a 1/2 inch (12.7 mm) PVC pipe  
(FIG. 2-2).  
3. Slope condensate tubing down and away from the  
boiler into a drain or condensate neutralizing filter.  
Condensate from the SYNC will be slightly acidic  
(typically with a pH from 3 to 5). Install a neutralizing  
filter if required by local codes.  
A Neutralizer Kit (FIG. 2-2) is available from the factory  
(KIT3046).  
1/2" (12.7 mm) PVC TEE ASSEMBLY  
(FACTORY SUPPLIED)  
4. Install the 1/2 inch (12.7 mm) PVC tee assembly  
(shipped with the unit) as shown in FIG. 2-2.  
1/2" (12.7 mm) PVC UNION  
(FACTORY SUPPLIED)  
5. Leave the top of the 1/2 inch (12.7 mm) tee OPEN. This  
is needed as a vacuum break.  
NEUTRALIZER KIT  
FLOOR DRAIN  
OR DRAIN PAN  
6. Do not expose condensate line to freezing temperatures.  
7
User’s Information Manual  
2 Maintenance schedule  
Have leaks fixed at once by a qualified  
service technician. Failure to comply could  
result in severe personal injury, death, or  
substantial property damage.  
Check automatic air vents  
ƽ WARNING  
1. Reference FIG. 2-3 below.  
2. Remove the caps (FIG. 2-3 – A) from the automatic air  
vents in the system and check operation by slightly  
depressing valve “B” (FIG. 2-3) with the tip of a  
screwdriver.  
3. Replace the front access door.  
Operate relief valve  
1. Before proceeding, verify that the relief valve outlet has  
been piped to a safe place of discharge, avoiding any  
possibility of scalding from hot water.  
3. If the air vent valve appears to be working freely and not  
leaking, replace cap A”, twisting the cap all the way on.  
4. Loosen cap A” one turn to allow vent to operate.  
To avoid water damage or scalding due to  
ƽ WARNING  
valve operation, a metal discharge line  
5. Have the automatic air vent(s) replaced if it does not  
operate correctly.  
must be connected to the relief valve outlet  
and run to a safe place of disposal. This  
discharge line must be installed by a  
qualified heating installer or service  
technician in accordance with the  
instructions in the SYNC Installation and  
Operation Manual. The discharge line  
must be terminated so as to eliminate  
possibility of severe burns or property  
damage should the valve discharge.  
Figure 2-3 Automatic Air Vent  
CAP “A”  
REMOVE CAP “A”  
TO ACCESS VALVE “B”  
2. Read the boiler pressure/temperature gauge to make  
sure the system is pressurized. Lift the relief valve  
top lever slightly, allowing water to relieve through  
the valve and discharge piping.  
3. If water flows freely, release the lever and allow the valve  
to seat. Watch the end of the relief valve discharge pipe  
to ensure that the valve does not weep after the line has  
had time to drain. If the valve weeps, lift the seat again to  
attempt to clean the valve seat. If the valve continues to  
weep afterwards, contact your qualified service  
technician to inspect the valve and system.  
Test low water cutoff (if installed)  
1. If the system is equipped with a low water cutoff, test the  
low water cutoff periodically during the heating season,  
following the low water cutoff manufacturer’s  
instructions.  
4. If water does not flow from the valve when you lift the  
lever completely, the valve or discharge line may be  
blocked. Immediately shut down the boiler, following  
the operating instructions on page 9 of this manual. Call  
your qualified service technician to inspect the boiler and  
system.  
Reset button (low water cutoff)  
1. Testing the low water cutoff shuts the unit off. Press the  
RESET button on the low water cutoff to turn the unit  
back on.  
Shut boiler down (unless boiler is used  
for Domestic Water)  
Check boiler piping (gas and water)  
1. Remove the boiler front access door and perform a gas  
leak inspection per steps 1 through 7 of the Operating  
Instructions on page 9. If gas odor or leak is detected,  
immediately shut down the boiler following the  
procedure on page 9. Call a qualified service technician.  
1. Follow To Turn Off Gas to Appliance” on page 9 of this  
manual.  
2. Do not drain the system unless exposure to freezing  
temperatures will occur.  
3. Do not drain the system if it is filled with an antifreeze  
solution.  
2. Visually inspect for leaks around water piping.  
Also inspect the circulators, relief valve, and fittings.  
Immediately call a qualified service technician to repair  
any leaks.  
4. DO NOT shut down boilers used for domestic water  
heating, they must operate year-round.  
8
User’s Information Manual  
3 Operating instructions  
FOR YOUR SAFETY READ BEFORE OPERATING  
WARNING: If you do not follow these instructions exactly, a fire or explosion  
may result causing property damage, personal injury, or loss of life.  
A. This appliance does not have a pilot. It is  
equipped with an ignition device which  
automatically lights the burner. Do not try  
to light the burner by hand.  
B. BEFORE OPERATING smell all around  
the appliance area for gas. Be sure to  
smell next to the floor because some gas  
is heavier than air and will settle on the  
floor.  
Immediately call your gas supplier from a  
neighbor’s phone. Follow the gas supplier’s  
instructions.  
If you cannot reach your gas supplier, call  
the fire department.  
C. Use only your hand to turn the gas control knob.  
Never use tools. If the handle will not turn by  
hand, don’t try to repair it, call a qualified service  
technician. Force or attempted repair may result  
in a fire or explosion.  
WHAT TO DO IF YOU SM ELL GAS  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified  
Do not try to light any appliance.  
Do not touch any electric switch; do  
not use any phone in your building.  
service technician to inspect the appliance and  
to replace any part of the control system and  
any gas control which has been under water.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information  
8. Turn gas shutoff valve clockwise to “ON”.  
Handle will be parallel to pipe.  
above on this label.  
2. Set the thermostat to lowest setting.  
9. Install top cover.  
3. Turn off all electric power to the  
10. Turn on all electric power to appliance.  
11. Set thermostat to desired setting.  
appliance.  
4. This appliance is equipped with an  
ignition device which automatically lights  
the burner. Do not try to light the burner  
by hand.  
12. If the appliance will not operate, follow the  
instructions “To Turn Off Gas ToAppliance” and  
call your service technician or gas supplier.  
5. Remove front door.  
6. Turn gas shutoff valves counterclockwise  
to “OFF”. Handle will be perpendicular to  
pipe. Do not force.  
7. Wait five (5) minutes to clear out any gas.  
If you then smell gas, STOP! Follow “B”  
in the safety information above this label.  
If you don’t smell gas, go to next step.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
2. Turn off all electric power to the appliance  
if service is to be performed.  
4. Turn gas shut off valves counterclockwise to  
“OFF”. Handle will be perpendicular to pipe.  
Do not force.  
5. Install front door.  
3. Remove front door.  
LBL20053 REVA  
9
User’s Information Manual  
4 SMART TOUCH control module  
SYNC control module  
The Status Screen displays boiler status, Cascade addresses, outlet water temperature, inlet water temperature, system  
temperature, and tank temperature.  
The boiler can be changed by pressing the ON/OFF button. The Details Screen and Main Menu Screen can be accessed by  
pressing the appropriate button.  
Figure 4-1 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.  
Boiler Status - This line shows the current operating status of  
the SYNC boiler. Displayed items are as follows:  
• 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.  
• 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.  
• 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.  
• 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.  
• 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.  
10  
User’s Information Manual  
4 SMART TOUCH control module  
(continued)  
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 in the SYNC Service Manual 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 pages 12 - 13 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 14 of this  
manual for more information regarding this screen.  
11  
User’s Information Manual  
4 SMART TOUCH control module  
Figure 4-2 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.  
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 not 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.  
• 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.  
• 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.  
12  
User’s Information Manual  
4 SMART TOUCH control module  
(continued)  
Time - The time is displayed in the upper right-hand corner of  
the display. It is displayed in 24 hour format. Reference the  
night setback parameters in the SYNC Service Manual for  
information regarding adjusting the date and time.  
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 10 - 11 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 the SYNC Service Manual for more  
information regarding this shutdown.  
• Outlet Temp Shutdown - The outlet temperature has  
exceeded 195°F. Reference the SYNC Service Manual 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 14 for more information  
regarding this screen.  
• Flue Temp Shutdown - The flue temperature has  
exceeded 240°F. Reference the SYNC Service Manual for  
more information regarding this shutdown.  
Voltage too Low - The 120 VAC input to the control has  
dropped below 80 VAC. Reference the SYNC Service  
Manual for more information regarding this fault  
message.  
• Connect System Sensor - System sensor is not detected by  
Control Module 1. For proper operation of the SYNC  
boiler the system sensor must be connected.  
• Manual Shutdown - The boiler has been shutdown with  
the ON/OFF button on the Status Screen.  
13  
User’s Information Manual  
4 SMART TOUCH control module  
Use the Main Menu Screen (FIG. 4-3) to access the screens necessary to set temperatures, operating conditions, and monitor  
boiler operation.  
The SYNC is equipped with a SMART TOUCH control system. All menu options are accessed by touching the screen with your  
finger or a stylus from a PDA.  
Figure 4-3 Main Menu 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 the SYNC Service Manual for more information  
as follows:  
regarding the eight (8) accessible screens.  
• Setup - Allows access to seven (7) other screens for the  
Time - The time is displayed in the upper right-hand corner of  
adjustment of the control parameters.  
the display. It is displayed in 24 hour format. Reference the  
• Cascade - Shows the status of multiple boilers connected  
night setback parameters in the SYNC Service Manual for  
together in a cascade arrangement.  
information regarding adjusting the date and time.  
Temps - Shows the temperatures measured by the  
Status button - Pressing this button displays the Status Screen.  
This screen shows the current status of the SYNC boiler.  
Reference pages 10 - 11 for more information regarding this  
screen.  
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.  
• 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.  
14  
Notes  
15  
Revision Notes: Revision A (ECO #C02428) initial release.  
Revision B (ECO #C04062) reflects changes to the terminology in all  
SYNC manuals and labels from module to heat exchanger (exception:  
control module).  
SYNC-USER Rev B  
7/09  

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