SYNC-SER Rev H 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.
Contents CONTENTS........................................................................ 2 Hazard Definitions .............................................................. 2 PLEASE READ BEFORE PROCEEDING ......................... 2 Handling Ceramic Fiber Materials ...................................... 3 When servicing boiler ................................................... 3 Boiler operation............................................................ 3 Boiler water ....................................
Service Manual Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING WARNING The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).
Service Manual What is in this manual? Service Maintenance Near boiler piping • Service and maintenance schedules • Address reported problems • Inspect boiler area and boiler interior • Clean condensate trap • Check all piping for leaks • Check air openings • Flue vent system and air piping • Check water system • Check expansion tank • Check boiler relief valve • Inspect ignition electrode • Check ignition ground wiring • Check all boiler wiring • Check control settings • Perform start-up and checks • C
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.
Service Manual 1 Service The SYNC display 6
Service Manual 1 Service (continued) Control inputs SECONDARY SMART CONTROL MODULE LOW VOLTAGE CONNECTION BOARD PRIMARY SMART CONTROL MODULE SEQUENCER / BUILDING MANAGMENT SYSTEM OUTDOOR SENSOR O-TEMP 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 HW THERMOSTAT ROOM THERMOSTAT / ZONE CONTROL BLOCKED DRAIN SWITCH PRIMARY/SECONDARY FLUE GAS SENSOR LOW WATER CUT
Service Manual 1 Service Control outputs LOW VOLTAGE CONNECTION BOARD SECONDARY SMART TOUCH CONTROL MODULE PRIMARY SMART TOUCH CONTROL MODULE ALARM BELL RUN TIME CONTACTS HEAT EXCHANGER 1 / HEAT EXCHANGER 2 BOILER PUMP SEQUENCER / BUILDING MANAGEMENT SYSTEM SYSTEM PUMP TOUCH DISPLAY TOUCH PANEL INTERFACE HW PUMP IGNITOR PC INTERFACE BLOWER GAS VALVE 8
Service Manual 1 Service (continued) General Operation How the boiler operates Access modes The SYNC uses two (2) advanced stainless steel heat exchangers and two (2) electronic control modules that allow fully condensing operation. The blowers pull in gas and air and push flue products out of the boiler through the heat exchangers and flue piping. The control modules regulate blower speeds to control total boiler firing rate.
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. 1.
Service Manual 1 Service (continued) Parameter table Table 1B This table lists the parameters and where to access them SETUP SERVICE / SETUP PARAMETERS SET POINT PARAMETERS USER ACCESS INSTALLER ACCESS SEE 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
Service Manual 1 Service Table 1B (continued from previous page) This table lists the parameters and where to access them OUTDOOR RESET NIGHT SETBACK CASCADE PUMPS BMS INSTALLER ACCESS 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 Ye
Service Manual 1 Service (continued) Viewable and changeable control parameters Status Screen: When the ON/OFF switch is turned to the ON position, the first screen visible on the LCD display will be the Status Screen. This screen displays the current status of the SYNC boiler. The following items can be viewed or interacted with on the Status Screen: On/Off button - Pressing this button allows the boiler to be placed in either Manual Shutdown Mode or Standby Mode.
Service Manual 1 Service Boiler Configuration - This line shows the current configuration of the two control modules inside the unit. Hot Water Tank Temperature - This is the temperature as measured by the tank sensor in the hot water storage tank. Outlet Water Temperature - This is a calculated temperature based on the readings of the outlet temperatures of the two (2) heat exchangers. Time - The time is displayed in the upper right-hand corner of the display. It is displayed in 24 hour format.
Service Manual 1 Service (continued) Details Screen: 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.
Service Manual 1 Service 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. Displayed items are as follows: • Delta T Shutdown - The temperature rise between the inlet and outlet temperatures has exceeded 55°F. Reference page 53 for more information regarding this shutdown.
Service Manual 1 Service (continued) Main Screen: The Main Screen allows navigation to eight (8) additional screens which are used to set temperatures, operating conditions, and monitor boiler operation. These screens are as follows: • Setup - Allows access to seven (7) other screens for the adjustment of the control parameters. • Cascade - Shows the status of multiple boilers connected together in a cascade arrangement.
Service Manual 1 Service CAUTION Before changing parameters, note the settings so that the unit can be returned to its original operating parameters. Setup Screen: The Setup Screen allows access to seven (7) other screens for adjusting control parameters. These screens are as follows: If the password has been entered correctly, the Parameter Change Screen will appear. The Parameter Change Screen will display the parameter being changed, the previous setting of the parameter, and adjustment buttons.
Service Manual 1 Service (continued) Service/Setup Parameters Screen: The Service / Setup Screen allows access to 10 parameters. Those parameters are as follows: • Demand Configuration - Sets the configuration of the control modules inside the boiler. The configuration selections are: Demand Configuration 1: Cascade Set Point Thermostat based - the control modulates the boiler based on the user set point and the temperature of the controlling sensor.
Service Manual 1 Service • Maximum Service Time - 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. Maximum service time sets the length of time the boiler will stay in Service Mode if no buttons are pressed before reverting back to its original state. This parameter can only be changed by the installer.
Service Manual 1 Service (continued) Set Point Parameters Screen: The Set Point Screen allows access to 12 parameters. Those parameters are as follows: • User Set Point - Sets the water temperature set point for fixed temperature operation or the maximum temperature set point when the outdoor air sensor is used. This parameter can be changed by the user or the installer. The temperature range of this parameter is 50° to 190°F. The default value is 125°F.
Service Manual 1 Service Outdoor Reset Parameters Screen: When the outdoor air sensor is installed, the control will calculate the water temperature set point based on the outdoor air temperature. As the outdoor air temperature drops the water temperature set point increases. This feature allows the boiler to be more efficient in periods of mild weather.
Service Manual 1 Service (continued) • Boost Increment - If a system heat call last longer than the programmed boost time setting and there have been no Hot Water Generation calls, the control will increase the water temperature set point by the amount in this parameter. If the system heat call continues through another time period, the set point will be increased again.
Service Manual 1 Service Night Setback Parameters Screen: The Night Setback Screen allows access to 15 parameters. Those parameters are as follows: • Date and Time - The control uses an internal clock for the night setback feature and for logging of events. For these features to work correctly, the clock must be set when the boiler is first installed or any time the boiler has been powered off for more than 30 days. To set the clock, press the SELECT button in the upper righthand corner of the display.
Service Manual 1 Service (continued) Cascade Parameters Screen: Cascade Operation When multiple boilers are installed, they can be wired together in a cascade sequence. A maximum of eight (8) boilers can be controlled from a single control. In this application one boiler would be designated as the Leader and all others would be designated as Members. The designated Leader boiler determines the total output needed from the group based on the set point and the system sensor reading.
Service Manual 1 Service Pumps Parameters Screen: The Pumps Screen allows access to four (4) parameters. Those parameters are as follows: • Boiler Pump Delay - Sets the length of time the boiler pumps will run after a system heat call has been satisfied. This parameter can only be changed by the installer. The time range for this parameter is 0 minutes to 40 minutes. The default time is 30 seconds.
Service Manual 1 Service (continued) 0 - 10Vdc BMS Parameters Screen: ModBus Timeout 0-10Vdc Operation When the Demand Configuration parameter (see page 19) is set to either Cascade BMS Thermostat Based, Cascade BMS Voltage Based, Cascade Modbus BMS Thermostat Based, or Cascade Modbus BMS Voltage Based; a 0 - 10Vdc signal can be supplied to the terminal strip connection or through Modbus communications to control a single unit or a multiple unit cascade. The BMS Screen allows access to 11 parameters.
Service Manual 1 Service ModBus Timeout • BMS Modulation at Minimum Voltage - Determines the modulation rate of the unit or cascade when the BMS input voltage is at or below the setting of the BMS Voltage at Minimum Modulation parameter. This parameter is only active when the BMS Type is set to modulation rate. This parameter can only be changed by the installer. The range of this parameter is 0% to 100%. The default value is 14.5%.
Service Manual 1 Service (continued) Cascade Screen: The Cascade Screen provides the status of the cascade system. Items that can be viewed on the Cascade Screen are as follows: System Temperature - This is the water temperature as measured by the system sensor located in the system supply piping. Boiler Power Level Indicators - For each boiler present in the cascade a power level indicator will be present above its corresponding number.
Service Manual 1 Service 1 On 34 80 55 The Building Screen displays information that is specific to the Building Automation System and is being transmitted through the Modbus communication link: Modbus Address - This is the address of a specific SYNC boiler. This address is set by dip switches on the Modbus communication board. The value displayed here should be the same as the value of the dip switches. The Building Automation System should use this address to communicate with the boiler.
Service Manual 1 Service (continued) Temps Screen: The Temps Screen displays the various temperatures as measured by sensors connected to each control module. Items that can be viewed on the Temps Screen are as follows: • Heat Exchanger 1/2 Inlet - This is the water temperature as measured by the sensor located in the inlet of each heat exchanger. • Heat Exchanger 1/2 Outlet - This is the water temperature as measured by the sensor located in the outlet of each heat exchanger.
Service Manual 1 Service Burners Screen: This screen provides the status of the combustion air blowers and flame signals. Items that can be viewed on the Burners Screen are as follows: • Blower Power Level Indicator - Two (2) blowers are depicted on the display. The top blower corresponds with Heat Exchanger 1 or Top heat exchanger. The lower blower corresponds with Heat Exchanger 2 or Bottom heat exchanger. Beside each blower is a power level indicator.
Service Manual 1 Service (continued) Graph Select Screen: The Graphs Screen consists of two (2) different screens. The first screen is the Parameter Selection Screen. By pressing the box beside the desired item, a check will appear in the selected box and the control will graph the status of that item. A maximum of five (5) items can be graphed at one time. The second screen is accessed by pressing the NEXT button. Once the items to be graphed are selected, press the NEXT button to view the graph.
Service Manual 1 Service History Screen: The History Screen shows the status of various counters and faults for each control module. Selection of the control module to be viewed is accomplished by pressing the SELECT button. The control module being displayed is shown in the module box. Items that can be viewed on the History Screen are as follows: • Power Hours - Shows the number of hours the control has been powered on.
Service Manual 1 Service (continued) Service Mode Screen: The Service Mode Screen allows the individual control modules to override all other heat demands and operate at a full fire condition for the purpose of combustion analysis. Selection of the control module to be placed into Service Mode is accomplished by pressing the SELECT button. The control module being placed into Service Mode is shown in the module box. To place the unit into Service Mode, press the ON/OFF button until ON is displayed.
Service Manual 2 Maintenance Maintenance and annual startup Table 2A Service and Maintenance Schedules Service technician (see the following pages for instructions) Owner maintenance (see the SYNC User’s Information Manual for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Check boiler area Daily • Clean condensate trap and fill with fresh water •Check pressure/temperature gauge • Check for leaks (water, gas, flue, condensate) • Verify flu
Service Manual 2 Maintenance WARNING (continued) Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
Service Manual 2 Maintenance Flue vent system and air piping 1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed. 2. Verify that boiler vent discharge and air intake are clean and free of obstructions.
Service Manual 2 Maintenance (continued) Inspect ignition and flame sense electrodes 1. Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover. 2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones. 3. Replace ignition/flame sense electrode, making sure gasket is in good condition and correctly positioned. Check ignition ground wiring 1.
Service Manual 2 Maintenance (continued) Check flame signal 1. At high fire the flame signal shown on the display should be at least 10 microamps. 2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the flame sense electrode. 3. See Section 3 - Troubleshooting in this manual for other procedures to deal with low flame signal.
Service Manual 2 Maintenance Test low water flow conditions NOTICE This test is to be carried out once the SYNC boiler is completely piped in with adequate gas and water flow. Once the test is completed, ensure that the isolation valve is opened up to allow full water flow. Test procedure 1. Set the SYNC to operate with the demand configuration parameter set to 1 (Cascade Set Point ThermostatBased).
Service Manual 3 Troubleshooting Alarm Screen: If a fault occurs which requires a Manual Reset, the unit will go into a lockout condition and the Alarm Screen will be activated. The screen will switch between a black or red background every 5 seconds with the text “Alarm Unit Needs Servicing” shown on the display. A message box shows the alarm status of the two (2) control modules. Mod1 is for Control Module 1 and Mod2 is for Control Module 2.
Service Manual 3 Troubleshooting WARNING WARNING (continued) Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the boiler before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage. Figure 3-1 Control Module Fuses F3 - 1.25 AMP FUSE MAIN BOARD F4 - 3.
Service Manual 3 Troubleshooting Table 3A Troubleshooting Chart - No Display FAULT CAUSE - No 120 VAC supplied to unit. CORRECTIVE ACTION • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. • Check 120 VAC through the ON/OFF switch. • Check wiring harness connection between display board and main control board. Connect harness at both points. No Display - No voltage through the switch. • Replace switch. - Bad display board.
Service Manual 3 Troubleshooting (continued) Checking temperature sensors The boiler temperature sensors (inlet water, outlet water, system water, flue, and outdoor air) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor.
Service Manual 3 Troubleshooting Table 3E Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply gas problem. Natural gas pressures • Refer to Section 6 - Gas Connections of the SYNC should be between 4 inches w.c. (1.0 kPa) Installation and Operation Manual for detailed and 14 inches w.c. (3.5 kPa). LP gas information concerning the gas supply. pressures should be between 8 inches w.c. (2.0 kPa) and 14 inches w.c. (3.2 kPa). Noisy Operation - Gas/air mixture problem.
Service Manual 3 Troubleshooting (continued) Table 3F Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check boiler pump operation on a call for heat. Flow Switch/ LWCO Either the low water cutoff or the optional (will require a manual flow switch is not making. reset once condition has been corrected. Press the RESET button on the display to reset.) Blown fuse.
Service Manual 3 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • If 24 VAC is present at the main control board, check the wiring between the main control board and the gas valve. Replace the wiring if necessary. Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point.
Service Manual 3 Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • If 24 VAC is present at the main control board, check the wiring between the main control board and the gas valve. Replace the wiring if necessary. Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point.
Service Manual 3 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Automatic Reset High Limit: • Verify that the system is full of water and that all air has been properly purged from the system. • Verify that the boiler is piped properly into the heating system. Refer to Section 6 - Hydronic Piping of the SYNC Installation and Operation Manual for the proper piping methods for the SYNC.
Service Manual 3 Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Vent/air intake lengths exceed the maximum allowed lengths. Refer to Section 2 - General Venting of the SYNC Installation and Operation Manual for proper lengths.
Service Manual 3 Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION Air pressure switch contacts are open. CORRECTIVE ACTION • Check the wiring connections to switch. Wires should be connected to the common and normally closed terminals. • Vent/air intake lengths exceed the maximum allowed lengths. Refer to Section 2 - General Venting of the SYNC Installation and Operation Manual for proper lengths.
Service Manual 3 Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Internal Fault The main control board has detected an • Replace the main control board. internal fault. Writing to Memos The main control board has detected an • Replace the main control board. internal fault. CRC Parameters The main control board has detected an • Replace the main control board.
Service Manual 3 Troubleshooting Combustion Analysis Procedure Table 3H Flue Products 1. Turn the main power off to the boiler by placing the “On/Off” switch in the OFF position. Natural Gas 2. Remove the flue temperature sensors from the flue pipe connections. Note: Combustion measurements will be made at this point. 3. Turn the main power on to the boiler by placing the “On/Off” switch in the ON position. Propane CO2 O2 CO2 O2 8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9% 8.
Service Manual 3 Troubleshooting (continued) Gas valve adjustment procedure Models 1.3 - 1.5 If adjustment of the gas valve is deemed necessary, use the following procedures: (Note: The procedures below are model specific.) Locate the throttle adjustment screw on top of the gas valve, see FIG. 3-3. Using an Allen wrench, turn the screw a 1/4 turn counterclockwise to increase CO2 levels or a 1/4 turn clockwise to decrease CO2 levels.
Revision Notes: Revision A (ECO #C02428) initial release. Revision B (ECO #C03046) reflects changes made to the History, Details, and Graphs screen shots (pgs. 15, 33 and 34). Revision C (ECO #CO2918) reflects the addition of Tank Sensor Open on page 50. Revision D (ECO #C04062) reflects changes to the terminology in all SYNC manuals and labels from module to heat exchanger (exception: control module), edits made to the ceramic fiber material warning, removal of the stabilitor from FIG.
