Lochinvar XPN399 Installation Manual

XLP POOL PACKAGE INSTALLATION INSTRUCTIONS

FOR MODELS: XPN 399 – 800

INS70057 Rev C

The XLP pool package system is a high efficiency commercial condensing boiler, pre-piped package system from the factory to an indirect heat exchanger. 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 XLP is designed around a predetermined flow set by the manufacturer between the boiler and the indirect heat exchanger. The XLP 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.

FIG. 1_Component Location

XLP Pool Package

TABLE A

MODEL

RECOMMENDED

SYSTEM

WATER FLOW

CONNECTION SIZE

399 93 GPM 2.5"

500 117 GPM 2.5"

600 142 GPM 2.5"

700 166 GPM 3"

800 202 GPM 3"

Piping

Pool / spa connections to the indirect heat exchanger are SCH 80 CPVC. Pool water is designed to flow from right to left standing in front of the boiler (factory installed sensor is on the inlet side of the indirect heat exchanger, see FIG. 8).

The supply and return water piping to the indirect heat exchanger shall be no smaller than 2.5" for models 399 - 600 and 3" for models 700 - 800.

Throttling Valve

A ΔT 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).

Installation Instructions

To achieve the optimum operating efficiency of your XLP 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.

RECOMMENDED CLEARANCES:

BOILER - SEE KNIGHT XL BOILER I & O MANUAL INDIRECT HEX -- ALLOW 18” FOR SERVICE ON ALL SIDES

System Sensor Location

Cupro-Nickel Pool Heat Exchanger

Skid Mounted on Steel Frame

Air Inlet Connection

Gas Inlet

Flue Connection

Pressure Reducing Valve / Auto Fill Valve

Condensate Drain

Relief Valve

T&P Gauge

Flow Switch

Boiler Pump

399,000 to 800,000 BTUs

Expansion Tank

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.

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. 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.

TABLE B

Remote Wire Connection

WIRE GAUGE

MAXIMUM ALLOWABLE

LENGTH

12 GA 100 ft.

14 GA 75 ft.

16 GA 50 ft.

18 GA 30 ft.

FIG. 2_Low Voltage Connections

AUX. DEVICE PILOT SUPPLY

24VAC GND

AUX. DEVICE PROVING

GAS PRESSURE SWITCH

FLOW SWITCH

ALARM CONTACTS

RUNTIME CONTACTS

SYSTEM SENSOR

DHW TANK SENSOR

OUTDOOR SENSOR

SHIELD GROUND

0-10VDC EXTERNAL GND CONTROL

DHW THERMOSTAT

R W

ROOM THERMOSTAT / ZONE CONTROL

SHIELD GROUND

SEQUENCING

LOW WATER

CUTOFF

CN1

CN2

CN3

CN4

CN5

AUX. DEVICE

RELAY

FLOW SWITCH

SYSTEM SUPPLY SENSOR

BUILDING

MANAGEMENT

SYSTEM

110° HIGH LIMIT SENOR

COM

A B

FROM

BOILER

TO NEXT BOILER

(AUX) DHW SENSOR

LOW WATER

CUTOFF

TO REMOTE ENABLE

(JUMPER REQUIRED IF NOT USED)

SHIELD

INS70057 Rev C

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

Full Flow (reference FIG. 6)

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 7 & 8)

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 500 gallons per minute (GPM). If two XLP Pool Packages (800,000 Btu/hr) were installed, each of the pool packages would require 202 GPM for a total of 404 GPM of the pool water being diverted through the indirect heat exchangers while the other 96 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 6-8). 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.

Indirect Heat Exchanger

Installation Instructions

Heat exchangers should be installed downstream of the pumping and filtration equipment (reference FIG. 3).

FIG. 4_pH Scale

INS70057 Rev C

FIG. 3_Pumping and Filtration Equipment

FILTRATION

SYSTEM PUMP

FROM POOL

TO POOL

CHLORINATOR

(DOWNSTREAM)

TOP VIEW

Pool Water Chemistry

It is essential that the instructions in this section along with the Ryznar Stability Index and/or Calcium Stability Index are followed to prevent corrosion / erosion of the indirect heat

exchanger:

- Always keep pH to within correct levels. The ideal pool pH should be kept to within 7.4 to 7.6.

- Under no circumstances should the pH fall below 7.2 or rise above 7.8 (see FIG. 4). Check on a day-to-day basis. Alter pool condition as necessary.

- Ensure that chlorine levels are within the range recommended by the chemical manufacturer and are in accordance with the type of pool, for example; private, hotel, school or municipal.

- If a bypass is fitted to the indirect heat exchanger circuit, it is essential that any or all of the valves are correctly positioned to allow the recommended pool water flow to pass through the heat exchanger.

- The system filter unit should be checked regularly, especially sand filters (to detect sand and diatomaceous earth). Sand filters, if working incorrectly, can allow sand to pass around the pool circuit causing erosion of the pipework and heat exchanger. Keep the pool free from debris such as leaves, grass cuttings, etc. This foreign matter can cause decay and increase pH.

- It is essential that the correct amount of chlorine dosage is added to the pool. To allow proper dispersion of the dose in the pool water, distribute the chemicals to various areas of the pool. Do not dose in one area only, as this will create high acidic areas which can cause corrosion / erosion of the pool equipment.

- Chlorinator should be installed downstream of the XLP.

Filling the System

The boiler is filled through the pressure reducing auto-fill valve. The operating pressure of this system is 15 psi between the heater and the indirect heat exchanger. There are no adjustments necessary to the fill valve cartridge (factory set). The expansion tank is set at 20 psi. It is necessary to check the pressure of the expansion tank when annual maintenance is performed. The boiler system operates off a city or potable water system which feeds a closed loop system. A hard line is piped from the potable water supply to the pressure reducing valve. This water is to remain on at all times when the system is in operation.

Pressure Reducing Valve

The valve is equipped with a fast-fill feature that can be used to override normal operation when filling and purging the system. To activate fast-fill, push and hold down the fast-fill knob on top of the cartridge as shown in FIG. 5.

Relieve air from the system through operation of the pressure relief valve by pulling the lever on top of the valve, causing it to open.

FIG. 5_Pressure Reducing Auto-Fill Valve

PUSH CAP DOWN TO ACTIVATE FAST FILL

7.4 - 7.6

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