3 Troubleshooting
Combustion Analysis Procedure
1.Turn the main power off to the boiler by placing the “On/Off” switch in the OFF position.
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.
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 turning the heat exchanger on by pressing the ON/OFF button (OFF indicates that the heat exchanger is off and ON indicates that the heat exchanger should be firing).
6.Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor.
Note: Heat Exchanger 1 is the top heat exchanger; please ensure the probe is in the top flue sensor location.
7.Once the heat exchanger has modulated up to full fire measure the combustion. The values should be in the range listed in Table 3H above. CO levels should be less than 200 ppm for a properly installed unit. If the combustion is not within range reference the chart below for possible causes and corrective actions.
Service Manual
Table 3H Flue Products
Natural Gas | Propane | ||
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CO2 | O2 | CO2 | O2 |
8.0% - 10% | 3.0% - 6.5% | 9.0% - 11% | 4.1% - 6.9% |
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8.Once the Heat Exchanger 1 analysis is complete, test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that Heat Exchanger 1 shuts down and registers an alarm. Open the manual shutoff valve, reset the control, and return to Service Mode.
9.Repeat the same procedure for Heat Exchanger 2 by selecting Heat Exchanger 2 while on the Service Mode Screen. Be certain to insert the probe from the combustion analyzer into the Heat Exchanger 2 flue temperature sensor location.
10.Turn the main power off to the boiler and replace the flue temperature sensor into the flue pipe connection.
11.Place the boiler back into normal operation.
WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into
the room. Failure to comply could result in severe personal injury, death, or substantial property damage.
Table 3G Troubleshooting Chart - Combustion Levels
POSSIBLE CAUSE | CORRECTIVE ACTION |
•Refer to Section 2 - General Venting of the SYNC Installation and Operation Manual Vent/Air Intake Length for the proper venting and air intake methods for the SYNC boiler.
or Obstruction
•Check for obstructions at the vent/air intake terminals.
Gas Supply Pressure | • Refer to Section 6 - Gas Connections of the SYNC Installation and Operation | |
| Manual for the proper gas supply for the SYNC boiler. | |
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Dirty/Damaged Burner | • Refer to page 39 of this manual for burner removal and cleaning procedures. | |
• Replace burner if necessary. | ||
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Gas Valve Adjustment | • Refer to page 55 of this manual for the gas valve adjustment procedure. |
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