Lochinvar XPN1.5 Installation Manual

INS70111 Rev B

AQUAS™ POOL PACKAGE INSTALLATION INSTRUCTIONS

FOR MODELS: XPN 1.0, 1.3 and 1.5

AQUAS Pool Package

The AQUAS pool package system is a high efficiency commercial condensing boiler package system pre-piped to an indirect heat exchanger from the factory. This pool heater is a low temperature operating system designed to take advantage of the stainless steel heat exchanger and condensing operating temperatures to ensure the highest efficiency possible. The AQUAS is designed around a predetermined flow, set by the manufacturer, between the boiler and the indirect heat exchanger. The AQUAS operates off the pool system pump itself which will continually supply water to the indirect heat exchanger. This means there is no need to purchase a dedicated circulator to deliver water to this package system.

Installation Instructions

Piping

Pool / spa connections to the indirect heat exchanger are SCH 80 CPVC glue fittings. The connections from the field loop to the heat exchanger are to be done in CPVC pipe as follows:

• Use cement on the connections so they are rated for CPVC pipe and have enough body to hold the connection.

• To make the connection, apply glue to both the CPVC flange and the section of pipe.

• Insert the pipe into the flange until it reaches the bottom of the flange.

• Turn the pipe a half turn in the socket to ensure that a proper seal is made.

To achieve the optimum operating efficiency of your AQUAS it is recommended that you keep the pool water flow of each appliance within plus or minus five gallons per minute of the recommended flow as stated in Table A. Low flow through the indirect heat exchanger will result in elevated temperatures supplied to the pool.

TABLE A

RECOMMENDED

MODEL

1.0 243 4"

1.3 316 6"

1.5 364 6"

RECOMMENDED CLEARANCES:

BOILER - SEE SYNC I & O MANUAL INDIRECT HEX - ALLOW 18" FOR SERVICE ON ALL SIDES

SYSTEM

WATER FLOW

CONNECTION SIZE

FLUE

CONNECTION

GAS INLET

Pool water is designed to flow from right to left standing in front of the boiler. A factory installed sensor is on the inlet side of the indirect heat exchanger (FIG. 9, page 7).

The supply and return water piping to the indirect heat exchanger shall be no smaller than 4" for Model 1.0 and 6" for Models 1.3 and 1.5.

Throttling Valve

A T of 8° - 10°F across the indirect heat exchanger is recommended. Throttling valves are used to set the flow through

the indirect heat exchanger. (Standard gate valves are acceptable.)

FIG. 1_Component Location

PRESSURE REDUCING

VALVE / AUTO FILL VALVE

EXPANSION

TAN K

SYSTEM SENSOR

LOCATION

CUPRO-NICKEL POOL

HEAT EXCHANGER

SKID MOUNTED

ON STEEL FRAME

BOILER

PUMP

IMG00196

RELIEF VALVE

CONDENSATE DRAIN

1,000,000 - 1,500,000 BTU’S

TEMPERATURE AND PRESSURE GAUGE

NOTE: Model 1.5 shown for illustration purposes only.

The system can be installed in either a Full Flow or Diverted Flow orientation:

Full Flow (reference FIG. 7)

If the total system flow of the swimming pool or spa system is within five gallons per minute of the recommended system water flow as shown in Table A on page 1, this type of system is recommended.

Diverted Flow (reference FIG.’s 8 & 9)

Apply a small amount of a high quality RTV silicone sealant to the threads to prevent leaks and install the limit and bulbwell into the threaded opening in the pipe. Install the limit control and bulbwell and tighten to seal. Do not over-tighten either part into the threaded opening in the PVC pipe. Over tightening can damage the parts and/or strip the threads cut into the plastic pipe. Wire the 110°F limit into the pool heater control circuit as shown in FIG. 2 on page 3. If additional wire length is needed, use 18 gauge wire for distances up to 30 feet. For longer distances, size the wire per Table B.

Criteria for installing a diverted flow system is as follows:

• If the total system flow is greater than the amount required by the indirect heat exchanger.

• Installations with temperatures in excess of 95°F. This is necessary so the pool high limit will not trip. No water should enter the pool / spa in excess of 110°F. If the heat exchanger pool outlet is in excess of 110°F the water must be tempered down.

• Multiple unit installation.

Example: Total system flow is 1000 gallons per minute (GPM). If two 1,500,000 Btu/hr units were installed, each of the pool packages would require 364 GPM for a total of 728 GPM of the pool water being diverted through the indirect heat exchangers, while the other 272 GPM would be diverted back to the pool.

Auxiliary Mixed Water Limit Control

Ensure that the auxiliary 110°F mixed water limit control is installed in the filter system piping. Install the auxiliary limit a minimum of three feet downstream from the point where the heated water from the indirect heat exchanger is added to the filtration system (see FIG.’s 7 - 9). If the water leaving the heat exchanger is in excess of 110°F a bypass must be installed to temper the water below 110°F before re-entering the pool/spa.

TABLE B

Remote Wire Connection

WIRE GAUGE

12 GA 100 ft.

14 GA 75 ft.

16 GA 50 ft.

18 GA 30 ft.

MAXIMUM ALLOWABLE

LENGTH

The limit will be mounted in a 3/8" NPT tapped fitting installed in the filtration system piping or it may be installed directly into a tapped opening in the PVC filter system piping. Turn off the filter system pump when installing the auxiliary limit in the filtration system piping. Tapped openings can be added to the PVC pipe by first drilling 9/16" pilot holes in the PVC pipe at least three feet downstream of the point where the heated water from the indirect heat exchanger is added to the filter piping. The drilled pilot holes can now be carefully threaded with a 3/8" NPT tap. After the pipe threads have been cut into the PVC pipe wall the limit and bulbwell can be inserted into the tapped openings.

INS70111 Rev B

FIG.2_Low Voltage Connections

1 ALARM

2 CONTACTS

3 RUN TIME

4 CONTACTS

5 LOUVER

MOD BUS

LBL20052 REV

ENABLE

7 MODULE 2

8 FLOW SWITCH

9 MODULE 1

6 PROVING

10 FLOW SWITCH

11 TANK

12 THERMOSTAT

13 R

15 SHIELD GND

14 W

16 A

17 B

0 - 10V INPUT

21 SYSTEM

20 (-)

18 SHIELD GND

22 SENSOR

19 (+)

23 OUT DOOR

24 SENSOR

CASCADE

26 SENSOR

25 TANK

27 SHIELD GND

30 SHIELD GND

29 A

28 B

SHIELD

MODBUS COMMUNICATION BUS

TO NEXT BOILER

R E L

OI B

SHIELD

BUILDING

MANAGEMENT

SYSTEM

D L

E L

I H

B S

I EV

R P

OM FR

MODULE 2

110v HIGH LIMIT SENSOR

MODULE 1

TANK

THERMOSTAT

SYSTEM SENSOR

ENABLING DEVICE

TANK SENSOR

IMG00232

INS70111 Rev B

Line Voltage Connections

The AQUAS pool package has a single point line voltage connection for the boiler and the pump (FIG. 3). Connect 120 VAC wiring to the line voltage terminal strip in the junction box. Provide and install a fused disconnect or service switch (20 amp recommended) as required by local codes. Refer to Table C for total amps by model.

Figure 3 Line Voltage Field Wiring Connections

120V SUPPLY

NEUTRAL W

GROUND G

Models

Total Amps

TABLE C

1.0 - 1.5

14.3

LINE

MODULE I

HOT WATER

GENERATOR

MODULE 2

HOT WATER

GENERATOR

SYSTEM PUMP

1.5HP/120V, 3HP/240V

MODULE I

BOILER PUMP

1.5HP/120V, 3HP/240V

MODULE 2

BOILER PUMP

1.5HP/120V, 3HP/240V

SERVICE SWITCH

G L

PUMP CONTROL

L2/W

INS70111 Rev B

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