Lochinvar 5 manuale d’uso

Installation & Operation Manual Models: 1.0 - 1.3 - 1.5 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 substantia[...]

2 Contents 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, wil[...]

Installation & Operation Manual Please read before proceeding 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 re[...]

Installation & Operation Manual 4 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 [...]

Installation & Operation Manual 22 43 8 9 7 41 33 36 39 37 24 32 2 22 4 1.0 Model Only 25 20 Left Side (inside unit) 6 23 5 26 14 24 15 29 Right Side (inside unit) The SYNC - How it works... (continued) 5 Models 1.0 - 1.3 - 1.5 40 13 1 12 31 28 17 19 42 27 30 34 3 2 18 21 11 35 38 16 44 Front View Rear View[...]

6 Installation & Operation Manual Ratings SYNC AHRI Rating Model Number Note: Change “N” to “L” for L.P. gas models. Input MBH (Note 4) Min Max Gross Output MBH (Note 1) Net AHRI Ratings Water, MBH (Note 2) SBN1000 100 1000 941 818 SBN1300 130 1300 1237 1076 SBN1500 150 1500 1444 1256 Other Specifications Appliance Water Content Gallons[...]

7 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 Co[...]

Installation & Operation Manual 8 6 " (152 40 MM) 24" (610 MM) REAR 0" LEFT OPEN FRONT 13" (330 MM) TOP 0" RIGHT 1/4” (6 MM) MINIMUM CLEARANCE A ROUND HOT W A TER PIPES 1” (25 MM) MINIMUM CLEARANCE A ROUND VENT PIPES Figure 1-2 Alcove Installation - Minimum Required Clearances 6" (152 MM) FRONT 4" (330 MM)[...]

Installation & Operation Manual 9 1 Determine boiler location (continued) 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 cleara[...]

Installation & Operation Manual 10 Products to avoid: Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners 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[...]

Installation & Operation Manual 1 Determine boiler location (continued) 11 When removing a boiler from existing common vent system: 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. [...]

1 Determine boiler location 12 Installation & Operation Manual 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, th[...]

13 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 cm 2 per kW). This opening must be located within 12" (30 cm) of the top of the enclosu[...]

14 Installation & Operation Manual Figure 2-1 Two Pipe Sidewall Termination - See page 22 for more details Direct venting options - Sidewall Vent 2 General venting Direct venting options - Vertical Vent Figure 2-3 Vertical Vent, Sidewall Air - See page 18 for more details Figure 2- 2 Two Pipe Vertical Termination - See page 26 for more details[...]

15 Installation & Operation Manual 2 General venting (continued) This appliance requires a special venting system. Use only approved stainless steel, PVC, CPVC or polypropylene pipe and fittings listed in Tables 2C, 2D, and 2F for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property d[...]

16 Installation & Operation Manual 2 General venting Requirements for installation in Canada 1. Installations must be made with a vent pipe system certified 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[...]

17 2 General venting (continued) Installation & Operation Manual Materials 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, Polypropylene or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent[...]

18 Model Vent Diameter Vent Min. Length Vent Max. Length Input De-Rate per 25 feet of Vent SB 1000 6" 12’ 100’ 0.63% SB 1300 6" 12’ 100’ 1.45% SB 1500 6" 12’ 100’ 1.65% Table 2B Room Air Minimum / Maximum Allowable Air / Vent Lengths Installation & Operation Manual 2 General venting Air contamination Pool and laundry [...]

19 Installation & Operation Manual 2 General venting (continued) Installing vent and air piping Use only cleaners, primers, and solvents that are approved for the materials which are joined together. 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. 2. Cut pipe [...]

20 Installation & Operation Manual 2 General venting The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 2E for approved vent adapters. Discard CPVC starter piece. NOTICE POLYPROPY LENE A DAPTE R IMG00024 Figure 2-7 Near Boiler Polypropyle[...]

21 Installation & Operation Manual 2 General venting (continued) Figure 2-8 Near Boiler Stainless Steel Venting The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 2F for approved vent adapters. Discard CPVC starter piece. NOTICE Stainless[...]

Installation & Operation Manual 3 Sidewall direct venting TO BOILER INT AKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTIO N VENT / AIR TERMINA TION GRADE OR SNOW LINE 12" MIN 12" MIN TO OVER- HANG POSSIBLE ORIENT A TIONS Do not exceed the maximum lengths of the outside vent piping shown in FIG.’s 3-1B and 3-1C. Excessive length exp[...]

23 Installation & Operation Manual 3 Sidewall direct venting (continued) Vent/air termination – sidewall 5. Maintain clearances as shown in FIG.’s 3-1A thru 3-4B, pages 22 and 24. Also maintain the following: a. Vent must terminate: • At least 6 feet (1.8 m) from adjacent walls. • No closer than 12 inches (305 mm) below roof overhang. ?[...]

24 Installation & Operation Manual 3 Sidewall direct venting Figure 3-4A PVC/CPVC Sidewall Termination Assembly Prepare wall penetrations 1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desire[...]

25 Installation & Operation Manual 3 Sidewall direct venting (continued) All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage. Multiple vent/air terminations 1. When terminating multiple SYNC boilers terminate each vent/air connection as described i[...]

26 Installation & Operation Manual 4 Vertical direct venting Prepare roof penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the ve[...]

27 Installation & Operation Manual 4 Vertical direct venting (continued) Multiple vent/air terminations 1. When terminating multiple SYNC boilers, terminate each vent/air connection as described in this manual (FIG. 4-3). Terminate all vent pipes at the same height and all air pipes at the same height to avoid recirculation of flue products and[...]

28 Installation & Operation Manual 5 Hydronic piping System water piping methods The SYNC is designed to function in a closed loop pressurized system not less than 12 psi (83 kPa). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet. It is important to note th[...]

Installation & Operation Manual Circulator sizing The SYNC heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graph in FIG. 5-4 for pressure drop through the SYNC heat exchanger. Near boiler piping connections ISOLATION VALVE (TYPICAL) DRAIN (TYPICAL) SYSTEM SUPPLY SENSOR (NOTICE: A SYSTEM SUP[...]

30 Installation & Operation Manual Figure 5-3 Pump Configuration 5 Hydronic piping Hot Water Generator pump sizing The SYNC has two (2) heat exchangers that require two (2) individual pumps for proper installation in the boiler loop and an additional two (2) pumps for the Hot Water Generator loop. Hot Water Pump Head Loss = Ft. of Head for Heat[...]

Installation & Operation Manual It is required that near boiler piping systems utilize Primary/Secondary configurations as shown in FIG.’s 5-5 and 5-6 only. The use of other near boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance. [...]

32 Installation & Operation Manual 5 Hydronic piping HOT WATER GENERATOR SYSTEM CIRCULA TOR AIR SEPERATOR MAKE UP WA TE R DRAIN POIN T (TYPICAL) SYSTEM SUPPLY SENSOR BALL VALVE (TYPICAL) HEAT EXCHANGER 2 BOILER PUMP PRESSURE RELIEF VALVE FLOW CHECK VALVE (TYPICAL) PRESS URE REDUCING (VALVE) EXPANSIO N TANK UNION (TYPI CAL) TEMPERATURE/ PRESSURE[...]

33 Installation & Operation Manual HOT W A T ER GENERA TOR SYSTEM CIRCULA TOR AIR SEP A RA TOR MAKE UP WA TER DRAIN POINT (TYPICAL) SYSTEM SUPPL Y SENSOR BALL V ALVE (TYPICAL) HEA T EXCHANGER 1 BOILER PUMP PRESSURE RELIEF VAL VE FLOW CHECK V ALVE (TYPICAL) PRESSURE REDUCING (VAL VE) EXP ANSION TAN K UNION (TYPICAL) TEMPER A TURE/ PRESSURE GAUGE[...]

34 Installation & Operation Manual 6 Gas connections Connecting gas supply piping 1. Refer to FIG. 6-1 to pipe gas to the boiler. a. Install ground joint union for servicing, when required. b. In Canada – When using manual main shutoff valves, it must be identified by the installer. 2. Install sediment trap / drip leg. Figure 6-1 Gas Supply P[...]

35 Installation & Operation Manual 6 Gas connections (continued) Use two wrenches when tightening gas piping at boiler (FIG. 6-2), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components. USE BACK UP WRENCH TO PREVENT P[...]

36 Installation & Operation Manual Table 6A Natural Gas Pipe Size Chart The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1 inch w.c. (249 Pa), the meter, reg[...]

37 Installation & Operation Manual  WARNING Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage. 14. Turn on the gas supply at the manual gas valve. 15. Turn the power switch to the “ON” position[...]

Installation & Operation Manual 7 Field wiring ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. If original wiring as supplied with boiler must [...]

39 Installation & Operation Manual Low voltage connections 1. Route all low voltage wires through the knockouts in the rear of the boiler, as shown in FIG. 7-2. 2. Connect low voltage wiring to low voltage connection board as shown in FIG. 7-3 on page 41 of this manual and the boiler wiring diagram. LOW VOL T AGE CONNECTION BOARD LOW VOL T AGE [...]

40 Installation & Operation Manual 7 Field wiring System supply sensor 1. By installing the system supply sensor into the supply of the primary loop, the temperature of the system supply can be controlled. The SMART TOUCH control automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system supply[...]

41 Installation & Operation Manual 7 Field wiring (continued) 1 ALARM LBL20052 REV B 30 SHIELD GND MOD BUS 0 - 10V INPUT 2 CONT AC TS 3 RUN TIME 4 CONT ACTS 5 L OUVER 6 PROVING 8 FLOW SWITCH 10 FL OW SWITCH 29 A 26 SENSOR 25 T ANK 24 SENSOR 23 OUT DOOR 22 SENSOR 21 SYSTEM 20 (-) 19 (+) 18 SHIELD GND 17 B 16 A 15 SHIELD GND 14 W 13 R 11 T ANK 12[...]

42 Installation & Operation Manual 8 Condensate disposal Condensate drain 1. This boiler is a high efficiency appliance that produces condensate. 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. 8-1). 3. Slope condensate tubing down and away from the boiler into a drain or conden[...]

43 Installation & Operation Manual 9 Start-up Check/control water chemistry Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies for hard wate[...]

44 Installation & Operation Manual 9 Start-up Check for gas leaks Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas le[...]

45 Installation & Operation Manual 9 Start-up (continued) Final checks before starting the boiler  Read the SYNC Service Manual to familiarize yourself with SMART TOUCH control module operation. Read this manual, page 46 for proper steps to start boiler.  Verify the boiler and system are full of water and all system components are correct[...]

46 Installation & Operation Manual F OR Y OUR SAFETY RE A D BE FORE OPER A TI NG WARN ING : If y ou do not f ol low these i ns tr uct ions exac tl y, a f i re or expl os ion may res ul t c ausi ng property damage, per s on a l i njury , or los s of l if e. A . T his ap p l ian ce doe s n ot h ave a pi lot . I t i s eq ui ppe d wit h an i gni t [...]

47 Installation & Operation Manual 9 Start-up (continued) Check flame and combustion (continued) 4. Navigate to the Service Mode Screen from the Status Screen by pressing the MAIN button and then the SERVICE MODE button. 5. On the Service Screen place Heat Exchanger 1 into operation by selecting Heat Exchanger 1 with the SELECT button and turni[...]

48 Installation & Operation Manual 6. If no other changes are necessary, press the BACK button to return to the Parameter List Screen. 7. Once all the necessary adjustments have been made, press the BACK button to return to the Setup Screen. 8. Press the SAVE button to program all changes made to the set points and return to the Status Screen. [...]

49 Installation & Operation Manual General How the boiler operates The SYNC uses advanced stainless steel heat exchangers and electronic control modules that allow fully condensing operation. The blowers pull in air and push flue products out of the boiler through the heat exchangers and flue piping. The control modules regulate blower speed to[...]

10 Operating information 50 Installation & Operation Manual Gradient limiting If during operation of the boiler the outlet water temperature is rising too quickly, the control will reduce the firing rate to its lowest setting. Outdoor air reset If an outdoor air sensor is connected, the control module will calculate the set point based on the p[...]

51 Installation & Operation Manual 10 Operating information (continued) Monitor external limits Connections are provided on the connection board for external limits such as flow switch and a louver proving switch. The SMART TOUCH control will shut off the burner and inhibit relighting whenever any of these external limits open. Run-time and ala[...]

10 Operating information 52 Installation & Operation Manual If the water temperature at the system supply sensor is less than the set point + the turn-off offset - the off-on differential, then the control will initiate a call for heat on the Cascade (see the SYNC Service Manual for an explanation of the offset and differential). The Leader wil[...]

10 Operating information (continued) 53 Installation & Operation Manual Sequence of operation 1. Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for a space heating call, HW pump relay output for a HW call). 2. The control confirms that the low water cutoff and flow switch (optional) contacts are closed[...]

10 Operating information 54 Installation & Operation Manual SYNC control module Figure 10-1 Status Screen 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 M[...]

10 Operating information (continued) 55 Installation & Operation Manual Boiler Configuration - This line shows the current configuration of the two control modules inside the unit. 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[...]

56 Installation & Operation Manual 10 Operating information Figure 10-2 Main Menu Screen Use the Main Menu Screen (FIG. 10-2) 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 y[...]

57 Installation & Operation Manual 11 Maintenance Maintenance and annual startup Table 11A Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems, if any • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fill with fresh water • Che[...]

58 Installation & Operation Manual 11 Maintenance 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 [...]

59 Installation & Operation Manual 11 Maintenance (continued) 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 discharg[...]

60 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 electr[...]

61 Installation & Operation Manual 11 Maintenance (continued) The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 62 of this manual. Failure to comply could result in severe personal injury.  WARNING Cleaning boiler heat exchanger For recommended materials; including brush, appropriate[...]

62 Installation & Operation Manual 11 Maintenance Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC)[...]

63 BOX DEPICTS OPTIONAL ITEMS LADDE R DIAGRA M LBL200 58 REV E CONTROL MODULE 2 X5-3 X2-1 GAS V ALVE GAS V AL VE RELAY X5-5 X5-13 X5-6 X5-12 1 2 4 5 TR1 X1-7 FLAME ROD SPAR K ROD 120 V AC LOW VO L TAGE HIGH VOL TA GE CAUTION HIGH VOL T AGE SP ARK LEAD BLOWER X2-2 NOTES: 1. Whe re possi ble, sw itch es are sho wn wit hout u tili ties ( gas, w ater o[...]

Installation & Operation Manual 12 Diagrams Figure 12-2 Ladder Diagram_Part 2 BOX DEPICTS OPTIONAL ITE MS 120 VAC 24 VA C 120VAC TERMINAL STR IP 120V SUPPLY "L" ON / OFF SWITCH X1- 6 B O ILER PU MP R E LA Y D HW PU M P R ELAY SYS T EM P U MP R EL A Y BL O WER R ELA Y X 1-4 X1-2 X 1 - 1 12 3 BLO WER X 1 - 5 X 6 - 8 X6-3 F5 X5- 7 X6 - 7[...]

Installation & Operation Manual 12 Diagrams (continued) Figure 12-3 Wiring Diagram BOX DEPICTS OPTIONAL ITEMS OUTLE T SENSO R N o tes: 1. All w i r i ng m ust be i ns tal led i n accor dan ce wi t h: l ocal , st at e, provi nci al and nat i onal co d e requi rem ent s pe r ei t her N. E. C . i n USA or C. S . A. i n Canada . 2. If any ori gi na[...]

66 Notes[...]

67 Notes[...]

Revision Notes: Revision A (ECO #C02428) initial release. Revision B (ECO #C03046) reflects the addition of FIG. 5-3 on page 27, the addition of a pressure gauge to FIG. 5-6 on page 30, edits made to FIG. 7-1 on page 35, edits made to the Low Water Cutoff Protection section on page 48 along with the addition of the Flow Sensing Device section. Revi[...]