Lochinvar SYNC 1.3 User Manual

SYNC-I-O Rev H

Installation & Operation Manual

Models: 1.0 - 1.3 - 1.5

 WARNING

Save this manual for future reference.

This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the SYNC Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Contents

HAZARD DEFINITIONS .................................................... 2

PLEASE READ BEFORE PROCEEDING ........................ 3

THE SYNC -- HOW IT WORKS...................................... 4-5

RATINGS ........................................................................... 6

1. DETERMINE BOILER LOCATION

Closet and Alcove Installations .......................................... 7

Provide Air Openings to Room .......................................... 9

Flooring and Foundation ................................................... 9

Vent and Air Piping ............................................................ 9

Prevent Combustion Air Contamination ............................. 9

Using an Existing Vent System to Install a New Boiler ... 10

Corrosive Contaminants and Sources ............................. 10

Removing a Boiler from Existing Common Vent .............. 11

Remove Boiler from Wood Pallet ..................................... 11

Combustion and Ventilation Air Requirements ........... 12-13

2. GENERAL VENTING

Direct Venting Options - Sdwl/Horz. Vent Opt. Rm Air .... 14

Direct Venting Options - Vert. Vent Opt. Rm Air ...............15

Direct Venting Options - Vert. Vent, Horz. Air ................. 16

Install Vent and Combustion Air Piping ........................... 17

PVC / CPVC Vent Piping Materials ............................ 17

PVC/CPVC Air Intake/Vent Connections ......................... 18

Air Inlet Pipe Materials ................................................ 18

Requirements for Installation in Canada .......................... 19

Installing Vent and Air Piping ........................................... 19

Stainless Steel Vent and Air Piping ................................. 20

Min./Max. Combustion Air & Vent Piping Lengths ........... 21

Vent and Air Piping .......................................................... 21

3. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall ................................... 22-25

Determine Location ................................................ 22-24

Prepare Wall Penetrations .......................................... 24

Termination and Fittings ............................................. 25

Multiple Vent/Air Terminations .................................... 25

4. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical .................................... 26-27

Determine Location ..................................................... 26

Prepare Roof Penetrations ......................................... 26

Termination and Fittings ........................................ 26-27

Multiple Vent/Air Terminations .................................... 27

Room Air .......................................................................... 27

5. HYDRONIC PIPING

System Water Piping Methods ......................................... 28

Low Water Cutoff Device ................................................. 28

Chilled Water System ....................................................... 28

Freeze Protection ............................................................. 28

General Piping Information .............................................. 28

Circulator Sizing ............................................................... 29

Near Boiler Piping Connections ....................................... 29

Near Boiler Piping Components .................................. 31-33

6. GAS CONNECTIONS

Connecting Gas Supply Piping ........................................ 34

Natural Gas ...................................................................... 35

Pipe Sizing for Natural Gas ........................................ 35

Natural Gas Supply Pressure Requirements ............. 35

Propane Gas .................................................................... 35

Pipe Sizing for Propane Gas ...................................... 35

Propane Supply Pressure Requirements ................... 35

Check Inlet Gas Supply .............................................. 36-37

Gas Pressure ................................................................... 37

Gas Valve Replacement .................................................. 37

7. FIELD WIRING

Line Voltage Connections ................................................ 38

Low Voltage Connections ................................................ 39

Wiring of the Cascade ...................................................... 40

8. CONDENSATE DISPOSAL

Condensate Drain ............................................................ 42

9. STARTUP ............................................................... 43-48

10. OPERATING INFORMATION

General ........................................................................ 49-51

Cascade ...................................................................... 51-52

Sequence of Operation .................................................... 53

Status Screen .............................................................. 54-55

Main Screen ..................................................................... 56

11. MAINTENANCE

Maintenance & Annual Startup .............................. 57-62

12. DIAGRAMS

Ladder Diagrams ................................................... 63-64

Wiring Diagram ........................................................... 65

Revision Notes .................................................. Back Cover

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

Please read before proceeding

Installation & Operation Manual

 WARNING

NOTICE

 WARNING

Installer – Read all instructions, including this manual and the SYNC Service Manual, before installing. Perform steps in the order given.

User – This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference.

Have this boiler serviced/inspected by a qualified service technician, at least annually.

Failure to comply with the above could result in severe personal injury, death or substantial property damage.

When calling or writing about the boiler – Please have the boiler model and serial number from the boiler rating plate.

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.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

When servicing boiler –

• 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.

• 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.

• 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.

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.

• 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.

• Do not use “homemade cures” or “boiler patent medicines”. Serious damage to the boiler, personnel, and/or property may result.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric 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.

• 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 in system components. Leaks in boiler or piping must be repaired at once to prevent the need for 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.

The SYNC - How it works...

1. Access cover - front

Provides access to the gas train and the heat exchanger.

2. Air intake adapter

Allows for the connection of the PVC air intake pipe to the boiler.

3. Air pressure switches

The air pressure switches detect blocked flue/vent conditions.

4. Air shrouds (1.0 Model only)

The air shrouds control air and gas flow into the burners.

5. Automatic air vents

Designed to remove trapped air from the heat exchanger coils.

6. Blowers

The blowers pull in air and gas through the venturis (item

35). Air and gas mix inside the blowers and are pushed into the burners, where they burn inside the combustion chamber.

7. Boiler drain port

Location from which the heat exchangers can be drained.

8. Boiler inlet temperature sensors

These sensors monitor system return water temperature. If selected as the controlling sensor, the control module adjusts the boiler firing rate so the inlet temperature matches the set point.

9. Boiler outlet temperature sensors

These sensors monitor boiler outlet water temperature. If selected as the controlling sensor, the control module adjusts boiler firing rate so the outlet temperature matches the set point.

10. Burners (not shown)

Made with metal fiber and stainless steel construction, the burners use pre-mixed air and gas and provide a wide range of firing rates.

11. Condensate drain connection

Connects the condensate drain line to a 1/2" PVC union.

12. Control modules

The control modules respond to internal and external signals and control the blowers, gas valves, and pumps to meet the heating demand.

13. Electronic display

Digital controls with touch screen technology and full color display.

14. Flame inspection windows

The quartz glass windows provide a view of the burner surfaces and flames.

15. Flame sensors

Used by the control module to detect the presence of burner flame.

16. Flap valves

Prevents recirculation of flue products when only one burner is running.

17. Flue gas sensors

These sensors monitor the flue gas exit temperature. The control modules will modulate and shut down the boiler if the flue gas temperature gets too hot. This protects the flue pipe from overheating.

18. Flue pipe adapter

Allows for the connection of the PVC vent pipe system to the boiler.

19. Gas connection pipe

Threaded 1½" pipe connection. This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.

20. Gas shutoff valves (inside unit)

Manual valves used to isolate the gas valves from the burners.

Installation & Operation Manual

21. Gas shutoff valve (outside unit)

Manual valve used to isolate the gas valve from the gas supply.

22. Gas valves

The gas valves sense the negative pressure created by the blowers, allowing gas to flow only if the gas valves are powered and combustion air is flowing.

23. Heat exchanger access covers

Allows access to the combustion side of the heat exchanger coils.

24. High gas pressure switches

Switches provided to detect excessive gas pressure.

25. High limits

Devices used to monitor the outlet water temperature. If the temperature exceeds its setting, they will break the control circuit, shutting the boiler down.

26. Ignition electrodes

Provides direct spark for igniting the burners.

27. Line voltage junction box

The junction box contains the connection points for the line voltage power and all pumps.

28. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

29. Low gas pressure switch

Switch provided to detect low gas pressure.

30. Low voltage connection board

The connection board is used to connect external low voltage devices.

31. Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage connection board.

32. Low water cutoff device (LWCO) Device used to ensure adequate water is supplied to the boiler

and in the event of inadequate water levels, will ensure the boiler will shut down.

33. Power switch

Turns 120 VAC ON/OFF to the boiler.

34. Pump relay boards

The pump relay boards are used to connect the boiler, system and Hot Water Generator (HW) pumps.

35. Relief valve

Protects the heat exchangers from an over pressure condition. The relief valve will be set at 50 PSI.

36. Reset switch

Reset switch for the low water cutoff. Hold for 10 seconds to reset.

37. Stainless steel heat exchangers

Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process.

38. Temperature and pressure gauge

Monitors the outlet temperature of the boiler as well as the system water pressure.

39. Test switch

Test switch for the low water cutoff. Hold for 10 seconds to test.

40. Top panel

Removable panel to gain access to the internal components.

41. Venturis

The venturis control air and gas flow into the burners.

42. Water inlets

Two 2" NPT water connections that return water from the system to the heat exchangers.

43. Water outlets

A 2½" NPT water connection that supplies hot water to the system.

The SYNC - How it works... (continued)

Models 1.0 - 1.3 - 1.5

Installation & Operation Manual

Front View

1.0 Model Only

Rear View

Left Side (inside unit)

Right Side (inside unit)

Ratings

Installation & Operation Manual

SYNC

I=B=R Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

Min Max

SBN1000 100 1000 941 818

SBN1300 130 1300 1237 1076

SBN1500 150 1500 1444 1256

NOTICE

Maximum allowed working pressure is located on the rating plate.

Input MBH

(Note 4)

Notes:

1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.

2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

3. SYNC boilers require special gas venting. Use only the vent materials and methods specified in the SYNC Installation and Operation Manual.

4. Standard SYNC boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

5. High altitude SYNC boilers are equipped to operate from 3,000 to 12,000 feet only with no field adjustments. The boiler will de-rate by 2% for each 1,000 feet above 3,000 feet. High altitude models are manufactured with a different control module for altitude operation, but the operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in FIG. A) is also affixed to the unit.

Gross

Output

MBH

(Note 1)

Other Specifications

Net

I=B=R

Ratings

Water,

MBH

(Note 2)

Figure A High Altitude Label Location

Appliance

Water Content Gallons

8.4 2½" (2) - 2" 1½" 6" 6"

10.0 2½" (2) - 2" 1½" 6" 6"

11.4 2½" (2) - 2" 1½" 6" 6"

Outlet Water

Inlet

Water

Gas

Connections

Vent

Size

Air

Size

(Note 3)

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

6. Ratings have been confirmed by the Hydronics Institute, Section of AHRI.

1 Determine boiler location

Installation & Operation Manual

Installation must comply with:

• Local, state, provincial, and national codes, laws, regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

• National Electrical Code.

• For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

NOTICE

The SYNC gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition.

Before locating the boiler, check:

1. Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

3. Check area around the boiler. Remove any combustible

materials, gasoline and other flammable liquids.

 WARNING

4. The SYNC must be installed so that gas control system

components are protected from dripping or spraying water or rain during operation or service.

5. If a new boiler will replace an existing boiler, check for

and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• Lack of freeze protection in boiler water causing system and boiler to freeze and leak.

Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

 WARNING

This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F (37.8°C).

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

This appliance requires a special venting system. Use only the vent materials, primer and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

Closet and alcove installations

A closet is any room the boiler is installed in which is less than 778 cubic feet for SB1000 models, 847 cubic feet for SB1300 models, and 914 cubic feet for SB1500 models.

An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.

Example: Room dimensions = 9 feet long, 9 feet wide, and 9 foot ceiling = 9 x 9 x 9 = 729 cubic feet. This would be considered a closet for a SYNC Boiler.

 WARNING

For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC or stainless steel vent material must be used inside the structure. The ventilating air openings shown in FIG.’s 1-1 and 1-2 are required for this arrangement. Failure to follow this warning could result in fire, personal injury, or death.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes – at least 1/4" (6 mm) from combustible materials.

2. Vent pipe – at least 1" (25 mm) from combustible materials.

3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance minimums.

Clearances for service access

1. See FIG.’s 1-1 and 1-2 on page 8 for recommended

service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space.

1 Determine boiler location

Installation & Operation Manual

Figure 1-1 Closet Installation - Minimum Required Clearances

1/4” (6 MM) MINIMUM CLEARANCE

ROUND HOT WATER PIPES

1” (25 MM) MINIMUM CLEARANCE

ROUND VENT PIPES

LEFT

24" (610 MM)

REAR

RECOMMENDED SERVICE CLEARANCES:

Front - 30" (762 mm) Top - 24" (610 mm) Left Side - 24" (610 mm) Rear - 24" (610 mm)

 WARNING

For closet installations, CPVC or stainless steel material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

4" (330 MM)

TOP

VENTILATING*

AIR OPENING

CLOSED DOOR

VENTILATING* AIR OPENING

6" (152 MM)

RIGHT

6" (152 MM)

FRONT

*AREA OF EACH OPENING: 1 SQ. INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ. INCHES

Figure 1-2 Alcove Installation - Minimum Required Clearances

1/4” (6 MM) MINIMUM CLEARANCE

ROUND HOT WATER PIPES

1” (25 MM) MINIMUM CLEARANCE

ROUND VENT PIPES

 WARNING

For alcove installations, CPVC or stainless steel material MUST BE used in an alcove structure due to elevated temperatures. Failure to

LEFT

24" (610 MM)

REAR

follow this warning could result in fire, personal injury, or death.

13" (330 MM)

TOP

OPEN FRONT

RECOMMENDED SERVICE CLEARANCES:

Front - 30" (762 mm) Top - 24" (610 mm) Left Side - 24" (610 mm)

RIGHT

Rear - 24" (610 mm)

1 Determine boiler location (continued)

Installation & Operation Manual

Provide air openings to room:

The SYNC alone in boiler room

1. No air ventilation openings into the boiler room are needed when clearances around the SYNC are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.

2. Combustion air openings are required when using the Room Air Option on page 27 of this manual.

The SYNC in same space with other gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ventilation air openings into the space.

 WARNING

2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the SYNC because it takes its combustion air from outside (direct vent installation).

The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the SYNC.

Do not install the boiler in an attic.

Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.

Flooring and foundation

Flooring

The SYNC is approved for installation on combustible flooring, but must never be installed on carpeting.

 WARNING

If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

Do not install the boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

Vent and air piping

The SYNC requires a special vent system, designed for pressurized venting.

The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see Section 4, Vertical Direct Venting. Note prevention of combustion air contamination below when considering vent/air termination.

Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the SYNC using any other means.

Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.

Prevent combustion air contamination

Install air inlet piping for the SYNC as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 10 for products and areas which may cause contaminated combustion air.

 WARNING

Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 10. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.

1 Determine boiler location

When using an existing vent system to install a new boiler:

 WARNING

Check the following venting components before installing:

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Installation & Operation Manual

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

• Material - For materials listed for use with this appliance, see Section 2 - General Venting, Table 2A. For stainless steel venting, an adapter of the same manufacturer (Table 2B) must be used at the flue collar connection.

• Size - To ensure proper pipe size is in place, see Table 2C. Check to see that this size is used throughout the vent system.

• Manufacturer - For a stainless steel application, you must use only the listed manufacturers and their type product listed in Table 2A for CAT IV positive pressure venting with flue producing condensate.

• Supports - Non-combustible supports must be in place allowing a minimum 1/4" rise per foot. The supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.

• Terminations - Carefully review Sections 2 through 4 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 2B for the manufacturer of the installed vent.

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

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

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

• Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 11.

With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on page 19.

 WARNING

If any of these conditions are not met, the existing system must be updated or replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Installation & Operation Manual

1 Determine boiler location (continued)

When removing a boiler from existing common vent system:

 DANGER

 WARNING

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting system. b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.

c. Test vent system – Insofar as is practical, close all building

doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

f. After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

g. Any improper operation of the common venting system

should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

Do not install the SYNC into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Remove boiler from wood pallet

1. After removing the outer shipping carton from the boiler, remove the parts package (packaged parts inside the jacket of the boiler).

2. To remove the boiler from the pallet:

a. Remove the front door of the boiler. b. Remove the two lag bolts from the wood pallet inside the boiler (FIG. 1-3). c. Detach the boiler from the lag bolts in the rear of the unit, see FIG. 1-3.

NOTICE

Figure 1-3 Boiler Mounted on Shipping Pallet

LAG BOLTS

(QTY. 3)

Maintain minimum specified clearances for adequate operation. All installations must allow sufficient space for servicing the vent connections, water pipe connections, piping and other auxiliary equipment, as well as the appliance. The clearance labels on each appliance note the same service and combustible clearance requirements as shown in this manual.

Multiple appliances may be installed in a modular boiler installation. Multiple appliances may be installed side by side with no clearance between adjacent appliances because this appliance is approved for zero clearance from combustible surfaces and no service access is required from the sides.

Consult the Venting section of this manual for specific installation instructions for the appropriate type of venting system that you will be using.

Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.

REAR

LAG BOLTS

(QTY. 3)

FRON

1 Determine boiler location

Combustion and ventilation air requirements for appliances drawing air from the equipment room

Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

The equipment room MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation.

Installation & Operation Manual

Figure 1-5_Combustion Air Through Ducts

2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11 cm2 per kW) of input (see FIG. 1-5).

Figure 1-4_Combustion Air Direct from Outside

1. If air is taken directly from outside the building with no duct, provide two permanent openings to the equipment room (see FIG. 1-4):

(a) Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW). This opening must be located within 12" (30 cm) of the bottom of the enclosure.

(b) Ventilation air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW). This opening must be located within 12" (30 cm) of the top of the enclosure.

IF NECESSARY

FOR TIGHT

CONSTRUCTION

Figure 1-6_Combustion Air from Interior Space

3. If air is taken from another interior space, each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/hr (22 cm2 per kW) of input, but not less than 100 square inches (645 cm2) (see FIG. 1-6).

1 Determine boiler location (continued)

Where two openings are provided, one must be within 12" (30cm) of the ceiling and one must be within 12" (30cm) of the floor of the equipment room. Each opening must have net free area as specified in the chart below (Table 1B). Single openings shall commence within 12" (30cm) of the ceiling.

 CAUTION

The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may

Figure 1-7_Combustion Air from Outside - Single Opening

4. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12" (30 cm) of the top of the enclosure (see FIG. 1-7).

Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI Z223.1; in Canada refer to the latest edition of CGA Standard CAN B149.1. Check all local code requirements for combustion air.

All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers.

be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the stainless steel heat exchanger, headers, flue collectors, and the vent system.

The result is improper combustion and a non-warrantable, premature appliance failure.

EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a downdraft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected immediately.

Installation & Operation Manual

Under no circumstances should the equipment room ever be under negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the unit.

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

FIG. 1-4 FIG. 1-5 FIG. 1-6 FIG. 1-7

Model

Number

1.0

1.3

1.5

*Outside Air from

2 Openings Directly from

Outdoors

Top

Opening, in

250

(1613 cm2)

325

(2097 cm2)

375

(2420 cm

Opening, in

(1613 cm2)

(2097 cm2)

)

(2420 cm2)

Bottom

250

325

375

*Outside Air from

2 Ducts Delivered from

Outdoors

Top

Opening, in

Bottom

500

(3226 cm2)

650

(4194 cm2)

750

(4839 cm2)

500

650

750

**Inside Air from

2 Ducts Delivered from

Interior Space

Top

Opening, in

1000

(6452 cm2)

1300

(8388 cm2)

1500

(9678 cm2)

Bottom

Opening, in

1000

(6452 cm2)

1300

(8388 cm2)

1500

(9678 cm2)

*Outside Air from 1 Opening Directly from Outdoors, in

333

(2149 cm2)

433

(2794 cm2)

500

(3226 cm2)

*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The above requirements are for the appliance only; additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances.

**Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”. For buildings of *“Tight Construction”, provide air openings into the building from outside.

*No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”.

*”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour).

2 General venting

Direct venting options - Sidewall Vent

Installation & Operation Manual

PVC/CPVC Two Pipe

See Figure 3-1A

Sidewall Vent Optional Room Air

Stainless Steel

Two Pipe

See Figure 3-2

PVC/CPVC

Room Air

See Figure 4-5

Stainless Steel

Room Air

See Figure 4-5

2 General venting (continued)

Direct venting options - Vertical Vent

Installation & Operation Manual

PVC/CPVC

Two Pipe

See Figure 4-1

Vertical Vent Optional Room Air

Stainless Steel

Two Pipe

See Figure 4-2

PVC/CPVC

Room Air

See Figure 4-5

Stainless Steel

Room Air

See Figure 4-5

Installation & Operation Manual

2 General venting

Direct venting options - Vertical Vent, Sidewall Air

PVC/CPVC

Vertical Vent, Sidewall Air

Stainless Steel

Vertical Vent, Sidewall Air

2 General venting (continued)

Install vent and combustion air piping

Installation & Operation Manual

 DANGER

The SYNC must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly installed vent and air system will cause severe personal injury or death.

PVC/CPVC vent piping materials

 WARNING

NOTICE

 WARNING

NOTICE

 WARNING

Use only the materials listed in Table 2A on page 19 for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

For closet and alcove installations, CPVC material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.

All PVC vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate).

This appliance requires a special venting system. Use only the vent materials, primer, and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

 WARNING

Figure 2-1A CPVC Starter Vent - Horizontal

CPVC PIPE

Figure 2-1B CPVC Starter Vent - Vertical

CPVC ELBOW

For all installations, the first ten (10) equivalent feet of vent must be CPVC or stainless steel (see FIG.’s 2-1A and 2-1B below). Failure to follow this warning could result in fire, personal inury, or death.

CPVC ELBOW

CPVC PIPE

2 General venting

Installation & Operation Manual

PVC/CPVC air intake/vent connections

1. Combustion Air Intake Connector (FIG. 2-2) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.

2. Vent Connector (FIG. 2-2) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Figure 2-2 Near Boiler PVC/CPVC Venting

VENT

PVC/CPVC ADAPTER FACTORY INSTALLED

AIR

Air inlet pipe materials:

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:

PVC, CPVC or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section. AL29-4C, stainless steel material to be sealed to specification of its manufacturer.

 WARNING

NOTICE

Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System:

a. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.

b. Do not install seams of vent pipe on the bottom of horizontal runs.

c. Secure all joints with a minimum of three sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe.

d. Ensure that the air inlet pipes are properly supported.

The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

Using vent or air intake materials other than those specified, failure to properly seal all seams and joints or failure to follow vent pipe manufacturer’s instructions can result in personal injury, death or property damage. Mixing of venting materials will void the warranty and certification of the appliance.

The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

2 General venting (continued)

Requirements for installation in Canada

Installation & Operation Manual

1. Installations must be made with a vent pipe system certified to ULC-S636.

IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636.

2. The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection.

3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/fittings. For concentric vent installations, the inner vent tube must be replaced with field supplied certified vent material to comply with this requirement.

 CAUTION

Improper installation of PVC or CPVC systems may result in injury or death.

Installing vent and air piping

NOTICE

1. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.

Use only cleaners, primers, and solvents that are approved for the materials which are joined together.

5. Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.

6. Priming and Cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces. b. Apply a liberal even coat of primer to the fitting socket. c. Apply a liberal even coat of primer to the pipe end to approximately 1/2" beyond the socket depth. d. Apply a second primer coat to the fitting socket. e. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket. f. While primer is still wet, apply an even coat of approved cement to the fitting socket. g. Apply a second coat of cement to the pipe. h. While the cement is still wet, insert the pipe into the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficient cement was not applied and joint could be defective. i. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.

3. Chamfer outside of each pipe end to ensure even cement distribution when joining.

4. Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

Table 2A PVC, Vent Pipe, and Fittings

All vent pipe materials and fittings must comply with the following:

Item Material

PVC Plastic Pipe, Schedules 40, 80, & 120 ANSI/ASTM D1785

PVC Plastic Pipe Fittings, Schedule 40 ANSI/ASTM D2466

Vent pipe

and fittings

PVC Plastic Pipe Fittings, Schedule 80 ANSI/ASTM D2467

PVC - DWV Pipe and Fittings ANSI/ASTM D2665

CPVC Plastic Pipe, Schedule 40 & 80 ANSI/ASTM F441

CPVC Plastic Pipe Fittings, Schedule 80 ANSI/ASTM F439

AL29-4C UL1738 ULC-S636

Standards for installation in:

United States Canada

CPVC and PVC venting must be

ULC-S636 Certified. IPEX is an

approved manufacturer in Canada

supplying vent material listed to

ULC-S636.

2 General venting

Installation & Operation Manual

When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

 DANGER

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.

Stainless steel vent and air piping

This product has been approved for use with stainless steel FasNseal vent systems manufactured by Dura-vent. Lochinvar offers a matching stainless steel sidewall vent termination kit, see Table 3A on page 22.

 WARNING

NOTICE

Use only the materials, vent systems, and terminations listed in Table 2B. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC-S636 approved system for Canada.

Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

NOTICE

The installer must use a specific vent starter adapter supplied by the vent manufacturer to adapt to different vent systems. See Table 2B for approved vent adapters.

Stainless steel air intake/vent connections

1. Combustion Air Intake Connector (FIG. 2-3) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table

305.4 or as local codes dictate.

2. Vent Connector (FIG. 2-3) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Figure 2-3 Near Boiler Stainless Steel Venting

NOTICE

PVC/CPVC or ABS is acceptable air inlet pipe material.

REMOVE PVC/CPVC VENT CONNECTOR WHEN INSTALLING STAINLESS STEEL

Table 2B Approved Stainless Steel Terminations and Adapters

STAINLESS STEEL VENT TERMINATION KITS

Kit Part Number Model Component Description

6" PVC x 6" Stainless Steel

Adapter

KIT30028 SB 1000 - 1500

KIT30029 SB 1300 - 1500

6" Stainless Steel Vent

Termination

6" Stainless Steel Air Inlet

6" PVC x 6" Stainless Steel

Adapter

6" Stainless Steel x 7"

Stainless Steel Adapters (2)

7" Stainless Steel Vent

Termination

7" Stainless Steel Air Inlet

The SYNC uses model specific combustion air intake and vent piping sizes as detailed in Tables 2C and 2D on page 21.

NOTICE

Increasing or decreasing combustion air or vent piping to sizes not specified in this manual is not authorized.

Installation & Operation Manual

2 General venting (continued)

Table 2C Direct Vent Minimum / Maximum Allowable Air / Vent Lengths

Model

SB 1000 6" 12’ 100’ 6" 12’ 100’ 1.25% SB 1300 6" 12’ 50’ 6" 12’ 50’ 2.90%

SB 1300 7" 12’ 100’ 7" 12’ 100’ 0.95% SB 1500 6" 12’ 50’ 6" 12’ 50’ 3.30% SB 1500 7" 12’ 100’ 7" 12’ 100’ 1.65%

Table 2D Room Air Minimum / Maximum Allowable Air / Vent Lengths

Note: When using a 7" vent or air pipe, a field supplied increaser is required.

When determining equivalent combustion air and vent length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) for each 45° elbow.

Air Intake

Diameter

Model

SB 1000 6" 12’ 100’ 0.63% SB 1300 6" 12’ 100’ 1.45%

SB 1500 6" 12’ 100’ 1.65%

Air Intake

Min. Length

Vent

Diameter

Air Intake

Max. Length

Min. Length

Vent

Diameter

Vent

Vent, air piping and termination:

The SYNC vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.

Vent

Min. Length

Vent

Max. Length

Vent

Max. Length

Input De-Rate per

De-Rate per

25 feet of Vent

Input

EXAMPLE: 20 feet (6 m) of PVC pipe + (4) 90° elbows + (3) 45° elbows = 49 equivalent feet (15 m) of piping.

Removing from existing vent

Follow the instructions in Section 1, page 11 of this manual when removing a boiler from an existing vent system.

Vent and air piping

Vent and air system:

NOTICE

You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion).

You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the SYNC using any other means.

 WARNING

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Use only approved stainless steel, PVC or CPVC pipe and fittings. For PVC/CPVC use with primer and cement specifically designed for the material used.

Air contamination

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.

Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. 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 this manual.

 WARNING

If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 10 before installing the boiler or air inlet piping.

If contaminants are found, you MUST:

• Remove products permanently. —OR—

• Relocate air inlet and vent terminations to other areas.

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