Lochinvar 1 manual

Service Manual Models: 1.0, 1.3, and 1.5 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 substantia[...]

2 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 [...]

3 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) has concluded, “Crystalline silica in the form of[...]

What is in this manual? Service Near boiler piping • Typical system components The SMART TOUCH display • Touch screen readout, buttons and their functions Control module inputs • Control module inputs and options Control module outputs • Control module outputs and options General • How the boiler operates • How the control module operat[...]

1 Service ISOLATION VALVE (TYPICAL) DRAIN (TYPICAL) SYSTEM SUPPLY SENSOR (NOTICE: A SYSTEM SUPPLY SENSOR MUST BE INSTALLED FO R PROPER BOILER OPERATION.) Y-STRAINER (RECOMMENDED) (TYPICAL) TEMPERATURE GAUGE RELIEF VALVE CHECK VALVE (TYPICAL) HEAT EXCHANGER 1 BOILER PUMP SYSTEM PUMP HEAT EXCHANGER 2 BOILER PUMP TO FLOOR DRAIN Near boiler piping This[...]

1 Service The SYNC display 6 Service Manual[...]

PRIMARY /SECONDARY GAS PRESSURE SW ITCH ROOM THERMOSTAT / ZONE CONTRO L FLOW SW I TCH SYSTEM SENSOR OUTDOOR SE NSOR SEQUENCE R / BUILDING MANAGME NT SYSTEM LOW VOLTA GE CONNECTION BOA RD PRIMARY /SECONDARY INLET TEMPERATURE SENSOR PRIMARY /SECONDARY OUTLET TEMPERATURE SENSOR PRIMARY /SECONDARY FLUE GAS SENSOR PRIMARY /SECONDARY HIGH LIMIT SENSOR PR[...]

LOW VOL T A GE CONNECTION BOA RD PRIM AR Y CONTROL MO DULE ALARM BELL RUN TIME CONT ACTS SEQU ENCER / BU ILDING MANAGEM ENT SYSTEM HEA T EXCHANGER 1 / HEA T EXCHANGER 2 BOILER PUMP SYSTEM PU MP HW PUMP IGNITOR BLOW ER GAS V AL VE PC INTERF ACE SE CONDAR Y SMART T OUCH CONTROL MO DULE TOUCH P ANEL INTERF ACE TOUCH DISPLA Y SMAR T TOUCH Control outpu[...]

General Operation How the boiler operates 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 con[...]

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 t[...]

Parameter table Table 1B This table lists the parameters and where to access them MENU DESCRIPTION SEE PAGE USER ACCESS INSTALLER ACCESS 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 BM[...]

MENU DESCRIPTION SEE PAGE USER ACCESS 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 Yes OUTDOOR RESET Date and t[...]

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 but[...]

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 - This is the water temperature as measured by the system supply sensor loc[...]

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 sh[...]

16 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 - [...]

17 Main Screen: 1 Service (continued) 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 statu[...]

Setup Screen: The Setup Screen allows access to seven (7) other screens for adjusting control parameters. These screens are as follows: • Service / Setup - Allows access to change service notification parameters, LCD backlight parameters, and temperature units. • Night Setback - Allows access to change the date and time and ON/OFF times for nig[...]

Service/Setup Parameters Screen: 1 Service (continued) 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 modu[...]

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 n[...]

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 [...]

1 Service 22 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. The O[...]

1 Service (continued) 23 • 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 inc[...]

1 Service 24 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 [...]

1 Service (continued) 25 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 desig[...]

1 Service 26 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[...]

1 Service (continued) 27 0 - 10Vdc BMS Parameters Screen: 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 t[...]

1 Service 28 • 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[...]

1 Service (continued) 29 Cascade Screen: The Cascade Screen provides the status of the cascade system. Items that can be viewed on the Cascade Screen are as follows: Boiler Power Level Indicators - For each boiler present in the cascade a power level indicator will be present above its corresponding number. The level will rise and fall indicating t[...]

1 Service 30 1 80 34 55 On 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. Boiler Enable - This di[...]

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 Exch[...]

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[...]

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 access[...]

History Screen: 1 Service 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 Hour[...]

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 bein[...]

2 Maintenance Maintenance and annual startup Table 2A Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fill with fresh water • Check for leaks (water, gas, flue, condensate) • V[...]

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 subs[...]

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. Failure to in[...]

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, mak[...]

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[...]

41 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. Figure 2-4 Adjust outlet isolation valve Test procedure 1. Set the SYNC to operate with[...]

3 Troubleshooting 42 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 th[...]

3 Troubleshooting (continued) 43 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. Never jumper (bypass) any device except fo[...]

3 Troubleshooting 44 Table 3A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION No Display - No 120 VAC supplied to unit. • 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 displ[...]

3 Troubleshooting (continued) 45 Table 3B - Inlet/Outlet System Sensor Resistance vs. Temperature Temperature Resistance Temperature Resistance 50 18,780 158 1,990 68 12,263 176 1,458 86 8,194 194 1,084 104 5,592 212 817 122 3,893 -- -- 140 2,760 -- -- Table 3C - Flue Temperature Sensor Resistance vs. Temperature Temperature Resistance Temperature [...]

3 Troubleshooting 46 Table 3E Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Noisy Operation - Supply gas problem. Natural gas pressures should be between 4 inches w.c. (1.0 kPa) and 14 inches w.c. (3.5 kPa). LP gas pressures should be between 8 inches w.c. (2.0 kPa) and 14 inches w.c. (3.2 kPa). • Refer to Section 6 - Gas Con[...]

3 Troubleshooting (continued) Table 3F Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flow Switch/ LWCO (will require a manual reset once condition has been corrected. Press the RESET button on the display to reset.) Either the low water cutoff or the optional flow switch is not making. • [...]

3 Troubleshooting 48 Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Burner Did Not Light (cont’d) (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) The unit has failed to prove main b[...]

3 Troubleshooting (continued) 49 Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Lost While Running (cont’d) (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) The unit was runnin[...]

Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Automatic Reset High Limit / HEX- Temp SW (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) Either the auto-reset high limit (optional), o[...]

3 Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Blower RPM’s Too High (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) The actual fan rpm is 30% higher t[...]

Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Air Flow Too Low (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) Air pressure switch contacts are open. • Check the wiring connections[...]

3 Troubleshooting (continued) 53 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 internal fault. • Replace the main control board. Writing to Memos The main control board has detected an internal f[...]

3 Troubleshooting Table 3G Troubleshooting Chart - Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION Vent/Air Intake Length or Obstruction • Refer to Section 2 - General Venting of the SYNC Installation and Operation Manual for the proper venting and air intake methods for the SYNC boiler. • Check for obstructions at the vent/air intake termin[...]

55 3 Troubleshooting (continued) Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary, use the following procedures: ( Note: The procedures below are model specific.) THROTTLE A DJUSTMENT SCREW Figure 3-2 Gas Valve Adjustment: Model 1.0 Model 1.0 Locate the throttle adjustment screw on top of the gas valve, see FIG. 3-2[...]

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 fro[...]