Lochinvar XPN400 Installation Manual

AQUAS POOL PACKAGE INSTALLATION INSTRUCTIONS

FOR MODELS: XPN 400/402 – 801/802

AQUAS Pool Package

The AQUAS 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 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

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.

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 may be done in CPVC or PVC 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.

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. 9).

The supply and return water piping to the indirect heat exchanger shall be no smaller than 2.5" for models 400/402 - 601/602 and 3" for models 701/702 - 801/802.

INS70064 Rev K

TABLE A

RECOMMENDED

MODEL

SYSTEM

CONNECTION SIZE

WATER FLOW

400/402 93 GPM 2.5"

501/502 117 GPM 2.5"

601/602 142 GPM 2.5"

701/702 166 GPM 3"

801/802 202 GPM 3"

RECOMMENDED CLEARANCES:

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

SYSTEM

SENSOR

LOCATION

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

AIR INLET

CONNECTION

GAS

INLET

CONNECTION

FLUE

FLOW SWITCH

CONDENSATE

DRAIN

RELIEF

VALV E

T&P GAUGE

CUPRO-NICKEL

OR TITANIUM

HEAT EXCHANGER

IMG01165

SKID MOUNTED

ON FRAME

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)

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 115°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 115°F. If the heat exchanger pool outlet is in excess of 115°F the water must be tempered down.

• Multiple unit installation.

Example: Total system flow is 500 gallons per minute (GPM). If two AQUAS 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 115°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 115°F a bypass must be installed to temper the water below 115°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.

INS70064 Rev K

Figure 2_Low Voltage Connections

SMART SYSTEM

MULTI-TEMP

LOOP CONTROL

BOILER

SHIELD SHIELD

2nd HEX OR DHW SENSOR

IMG00185

POOL HEX SENSOR

NOTE:

CONNECTION BOARD SPLIT FOR

ILLUSTRATION PURPOSES

B A

SYSTEM

BUILDING

MANAGEMENT

SPEED

CONTROL

SYSTEM PUMP

BOILER

PUMP

NEEDED

WIRE AS

FROM

BOILER

CUTOFF

LOW WATER

FROM FACTORY

JUMPER R1 TO W1

COM

115° HIGH LIMIT SENSOR

LOUVER RELAY

FLOW SWITCH

TANK THERMOSTAT

INS70064 Rev K

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 (15 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

GROUND

SERVICE

SWITCH

LINE

Model

Total

Amps

TABLE C

400/402 501/502 601/602 701/702 801/802

4.5 4.7 7.7 8.4 8.4

BOILER

PUMP

DOMESTIC

HOT WATER

PUMP / SECONDARY

HEX PUMP

G W

L2/N

INS70064 Rev K

Indirect Heat Exchanger

Installation Instructions

Heat exchangers should be installed downstream of the pumping and filtration equipment (reference FIG. 4).

FIG. 4_Pumping and Filtration Equipment

TOP VIEW

IMG00492

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. 5). 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

(DOWNSTREAM)

FILTRATION

SYSTEM

PUMP

POOL

FROM POOL

- Chlorinators must feed downstream of the pool heater and have an anti-siphoning device to prevent chemical backup in the heater when the pump is shut off.

CAUTION

High chemical concentrations from improperly adjusted feeders, chlorinators or salt levels above 5000 ppm can cause rapid corrosion to the heat exchanger.

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. 6.

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_pH Scale

INS70064 Rev K

7.4 - 7.6

FIG. 6_Pressure Reducing Auto-Fill Valve

PUSH CAP DOWN TO ACTIVATE FAST FILL

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