Summary of the content on the page No. 1
SYNC-SER Rev G
Service Manual
Models: 1.0, 1.3, and 1.5
WARNING This manual must only be
used by a qualified heating
installer / service technician.
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.
Summary of the content on the page No. 2
Contents Parameter Table.......................................................... 11-12 CONTENTS ........................................................................ 2 Viewable and Changeable Control Parameters .......... 13-35 Hazard Definitions .............................................................. 2 2. MAINTENANCE PLEASE READ BEFORE PROCEEDING ......................... 2 Maintenance and Annual Startup ................................ 36-41 Handling Ceramic Fiber Materials ...
Summary of the content on the page No. 3
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 WARNING 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).”
Summary of the content on the page No. 4
Service Manual What is in this manual? Service Maintenance � Service and maintenance schedules Near boiler piping � Address reported problems � Typical system components � Inspect boiler area and boiler interior � Clean condensate trap The SMART TOUCH display � Check all piping for leaks � Touch screen readout, buttons and their functions � Check air openings � Flue vent system and air piping Control module inputs � Check water system � Control module inputs
Summary of the content on the page No. 5
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
Summary of the content on the page No. 6
Service Manual 1 Service The SYNC display 6
Summary of the content on the page No. 7
Service Manual 1 Service (continued) Control inputs SECONDARY LOW VOLTAGE SMART CONTROL CONNECTION MODULE BOARD PRIMARY SMART CONTROL MODULE SEQUENCER / BUILDING MANAGMENT SYSTEM O-TEMP OUTDOOR SENSOR HEAT EXCHANGER SWITCH HW TANK SENSOR PRIMARY/SECONDARY INLET TEMPERATURE SENSOR SYSTEM SENSOR O-TEMP HEAT EXCHANGER SWITCH PRIMARY/SECONDARY OUTLET TEMPERATURE SENSOR FLOW SWITCH BLOCKED DRAIN SWITCH HW THERMOSTAT PRIMARY/SECONDARY FLUE GAS SENSOR ROOM THERM
Summary of the content on the page No. 8
Service Manual 1 Service Control outputs SECONDARY SMART TOUCH LOW VOLTAGE CONNECTION CONTROL MODULE BOARD PRIMARY SMART TOUCH CONTROL MODULE ALARM BELL RUN TIME CONTACTS HEAT EXCHANGER 1 / HEAT EXCHANGER 2 BOILER PUMP SEQUENCER / BUILDING SYSTEM PUMP MANAGEMENT SYSTEM TOUCH PANEL HW PUMP TOUCH DISPLAY INTERFACE IGNITOR PC INTERFACE BLOWER GAS VALVE 8
Summary of the content on the page No. 9
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
Summary of the content on the page No. 10
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 th
Summary of the content on the page No. 11
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 DISPLAY MODIFY Service/Setup 18 Yes Yes Yes Yes Night Setback 18 Yes Yes Yes Yes Set points 18 Yes Yes Yes Yes Cascade 18 Yes Yes Yes Yes Outdoor Reset 18 Yes Yes Yes Yes Pumps 18 Yes Yes Yes Yes BMS 18 Yes Yes Yes Yes Demand Conf 19 Yes No Yes No Serv Not Time 19 No No Y
Summary of the content on the page No. 12
Service Manual 1 Service Table 1B (continued from previous page) This table lists the parameters and where to access them USER ACCESS INSTALLER ACCESS SEE MENU DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY Reset T Lo Out 22 Yes No Yes No Reset T Hi Out 22 Yes Yes Yes Yes Out T Hi Reset 22 No No Yes Yes Out T Lo Reset 22 No No Yes Yes Out SD setp 22 No No Yes Yes Out SD df 22 No No Yes Yes Boost tim 22 No No Yes Yes Boost incr 23 No No Yes Yes Date and tim
Summary of the content on the page No. 13
Service Manual 1 Service (continued) Viewable and changeable control parameters Status Screen: When the ON/OFF switch is turned to the ON position, � SH BMS - The boiler has received a call for heat from the first screen visible on the LCD display will be the Status a 0-10 VDC BMS control. Screen. This screen displays the current status of the SYNC � Service Set Point Met - While in Service Mode, the boiler. The following items can be viewed or inter
Summary of the content on the page No. 14
Service Manual 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 Outlet Water Temperature - This is a calculated temperature the display. It is displayed in 24 hour format. Reference the based on the reading
Summary of the content on the page No. 15
Service Manual 1 Service (continued) Details Screen: � Alarm - Is ON when a fault has been detected and the The Details Screen is accessed by pressing the DETAIL button alarm contacts are closed. Is OFF when the alarm on the Status Screen. This screen shows the status of the contacts are open. various safeties, inputs and outputs to each control module. � Louver Proving Switch - Is ON when a remote proving Selection of the control module to
Summary of the content on the page No. 16
Service Manual 1 Service A blank message box is located on the Details Screen. This Time - The time is displayed in the upper right-hand corner of box will display various messages detailing the status of the the display. It is displayed in 24 hour format. Reference the control module. If a message is present in this box, the night setback parameters on page 24 for information regarding DETAILS button on the Status Screen will contain a yellow adjust
Summary of the content on the page No. 17
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 - All
Summary of the content on the page No. 18
Service Manual 1 Service Before changing parameters, note the settings so that the unit can be returned to its original operating CAUTION parameters. 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 These screens a
Summary of the content on the page No. 19
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 � Demand Configuration - Sets the configuration of the the BMS parameters on pages 27 and 28 for information control modules inside the boiler. The configuration regarding a
Summary of the content on the page No. 20
Service Manual 1 Service Reference page 18 for information regarding changing � Maximum Service Time - Service Mode allows the parameters. 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 Service Mode will override all other heat demands, the display. It is displayed in 24 hour format. Reference the however, all safeti
