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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 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.
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.