Lochinvar 1 User 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
substantial property damage.
WARNING
Save this manual for future reference.
SYNC-SER Rev G

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 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.
CONTENTS........................................................................ 2
Hazard Definitions.............................................................. 2
PLEASE READ BEFORE PROCEEDING......................... 2
Handling Ceramic Fiber Materials...................................... 3
When servicing boiler................................................... 3
Boiler operation............................................................ 3
Boiler water................................................................... 3
Freeze protection fluids................................................ 3
WHAT IS IN THIS MANUAL.............................................. 4
1. SERVICE
Near Boiler Piping.............................................................. 5
The SYNC Boiler Display................................................... 6
Control Inputs ............................................................... 7
Control Outputs............................................................. 8
General Operation........................................................ 9
Sequence of Operation.................................................... 10
Parameter Table.......................................................... 11-12
Viewable and Changeable Control Parameters.......... 13-35
2. MAINTENANCE
Maintenance and Annual Startup................................ 36-41
3. TROUBLESHOOTING
Alarm Screen.................................................................... 42
Before Troubleshooting.................................................... 43
Check Control Module Fuses .......................................... 43
Table 3A - Troubleshooting Chart - No Display ......... 44
Checking Temperature Sensors ...................................... 45
Table 3E - Troubleshooting Chart - Noisy System..... 46
Table 3F - Troubleshooting Chart - Fault Messages 47-53
Combustion Analysis Procedure...................................... 54
Table 3G-Troubleshooting Chart-Combustion Levels 54
Table 3H - Flue Products ........................................... 54
Gas Valve Adjustment Procedure.................................... 55
Revision Notes.................................................. Back Cover
Contents
Please read before proceeding
Installer – Read all instructions, including
this manual and the SYNC Installation
and Operation 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 SYNC 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 (see the SYNC
Installation and Operation Manual).
Any claims for damage or shortage
in shipment must be filed immediately
against the transportation company by the
consignee.
WARNING NOTICE

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 quartz or cristobalite from occupational
sources is carcinogenic to humans (Group 1).” Normal operating temperatures in this appliance are below
the level to convert ceramic fibers to cristobalite. Abnormal operating conditions would have to be created
to convert the ceramic fibers in this appliance to cristobalite.
The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic
materials it is advisable that the installer follow these safety guidelines.
Avoid breathing dust and contact with skin and eyes.
• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA
requirements for cristobalite at the time this document was written. Other types of respirators may
be needed depending on the job site conditions. Current NIOSH recommendations can be found on
the NIOSH website at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators,
manufacturers, and phone numbers are also listed on this website.
• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.
Apply enough water to the combustion chamber lining to prevent airborne dust.
Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.
Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer
thoroughly.
NIOSH stated First Aid.
Eye: Irrigate immediately.
Breathing: Fresh air.
WARNING
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.
• 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. Leaks in boiler piping must be repaired at
once to prevent the introduction of 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.
Service Manual

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 operates
• Access modes -- user and installer
• Sequence of operation -- Hot Water Generation
(HW)/space heating
Control panel menu access
• Accessing programming
mode and locating menus
(See separate guides covering the PC interface.)
Control panel parameter access
• Accessing and changing parameters from the touch screen
Quick start information -- parameter
table
• An index of available adjustments and readouts, where to
access them and where to find detailed information.
SYNC operation
• Service / Setup
• Set Points
• Outdoor Reset
• Night Setback
• Cascade
• Pumps
• BMS
Maintenance
• 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
• Check burner flame
• Check flame signal
• Check flue gas temperature
• General maintenance
• Review with owner
• Cleaning boiler heat exchanger
• Oiled bearing circulators
Troubleshooting
• Troubleshooting table - No display
• Checking temperature sensors
• Sensor tables
• Troubleshooting table - Fault messages displayed on
boiler interface
• Combustion analysis procedure
• Gas valve adjustment procedure
4
Service Manual

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 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.
5
Service Manual

1 Service
The SYNC display
6
Service Manual

PRIMARY/SECONDARY
GAS PRESSURE SWITCH
ROOM THERMOSTAT /
ZONE CONTROL
FLOW SWITCH
SYSTEM SENSOR
OUTDOOR SENSOR
SEQUENCER / BUILDING
MANAGMENT SYSTEM
LOW VOLTAGE
CONNECTION
BOARD
PRIMARY/SECONDARY INLET
TEMPERATURE SENSOR
PRIMARY/SECONDARY OUTLET
TEMPERATURE SENSOR
PRIMARY/SECONDARY
FLUE GAS SENSOR
PRIMARY/SECONDARY
HIGH LIMIT SENSOR
PRIMARY/SECONDARY
FLAME SENSOR
LOW WATER CUTOFF
BLOCKED DRAIN SWITCH
TOUCH PANEL
INTERFACE
PC INTERFACE
SECONDARY
SMART CONTROL
MODULE
PRIMARY
SMART CONTROL
MODULE
HW TANK SENSOR
HW THERMOSTAT
TOUCH DISPLAY
MODBUS COMMUNICATION
BOARD
O-TEMP
HEAT EXCHANGER SWITCH
O-TEMP
HEAT EXCHANGER SWITCH
IMG00004
Control inputs
1 Service (continued)
7
Service Manual

LOW VOLTAGE
CONNECTION
BOARD
PRIMARY
CONTROL MODULE
ALARM BELL
RUN TIME CONTACTS
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
HEAT EXCHANGER 1 /
HEAT EXCHANGER 2
BOILER PUMP
SYSTEM PUMP
HW PUMP
IGNITOR
BLOWER
GAS VALVE
PC INTERFACE
SECONDARY
SMART TOUCH
CONTROL MODULE
TOUCH PANEL
INTERFACE
TOUCH DISPLAY
SMART TOUCH
Control outputs
1 Service
8
Service Manual

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 control total boiler firing rate. The gas
valves sense the amount of air flowing into the boiler and
allow only the right amount of gas to flow.
How the control module operates
The SYNC control modules receive input from boiler sensors.
The control modules activate and control the blower and
gas valves to regulate heat input and switches boiler, Hot
Water Generation (HW) and system pumps on and off as
needed. The user/installer programs the control module to
meet system needs by adjusting control parameters. These
parameters set operating temperatures and boiler operating
modes.
Sequence of operation
Table 1A shows control module normal sequences of
operation for space heating and HW operation for each
individual control module. Additionally, the control
modules are programmed to synchronize their combined
modulation rates in order to maximize total boiler efficiency.
The combined operation sequence is for a typical application,
programmed to provide HW priority.
Access modes
User
The user can view all of the settings on the LCD screen. By
entering the user password (0704), the user can adjust the
User Set Point, Outdoor Shutdown, Night Setback, Boost,
HW Boiler Output Set Point, Backlight Time, and Backlight
Brightness settings.
Installer
Most parameters are available only to the installer, accessible
only by entering the installer access code (5309).
1 Service (continued)
9
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. 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.
3. The control starts the blower and closes the louver contacts to begin the Pre-Purge cycle.
4. The control confirms that the blower comes up to the desired speed, the flap valve opens, and the air pressure switch,
gas pressure switches, louver proving switch (field installed), and blocked drain switch contacts close.
5. Once the Pre-Purge cycle is complete, the control lowers the blower speed, initiates sparking of the ignition electrode,
and opens the gas valve.
6. After a short wait, the control stops sparking and checks for the presence of flame current through the spark and
flame sense electrodes.
7. If the control does not detect flame current, the control will lockout, until the RESET button on the touch screen
LCD is pressed.
8. If the control detects flame current, the control will hold the blower speed constant for a few seconds to allow the
flame to stabilize, then begin modulating the firing rate in order to maintain the controlling sensor to the desired set
point temperature.
9. If the current call for heat is for space heating and a HW call for heat becomes active, the control will turn on the HW
pump relay output, then turn off the boiler pumps. It will then modulate the blower speed in order to maintain the
outlet temperature to the desired HW outlet set point temperature.
10.
If the first heat exchanger in the boiler is unable to maintain the desired set point temperature, the second heat
exchanger in the boiler will be started, using much of the same sequences as described above. Once both heat
exchangers are firing, the controls will work in synchronization to maintain the desired set point temperature. If
the heat load should decrease sufficiently, the second heat exchanger will be shut down, much like the sequences
described below.
11. Once both the space heating and HW calls for heat are satisfied, the control will turn off the gas valve and begin the
Post-Purge cycle. Any pumps that are running will begin their respective Pump Delay cycles.
12. At the end of the Post-Purge cycle, the louver contacts will open.
13. The control verifies that the blower stops running and the flap valve closes.
14. At the end of the Pump Delay cycle(s), the pumps will be turned off.
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Service Manual