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. 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. 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. TABLE A 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 MODEL RECOMMENDED SYSTEM WATER FLOW CONNECTION SIZE 1.0 243 4" 1.3 316 6" 1.5 364 6" 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 RECOMMENDED CLEARANCES: BOILER - SEE SYNC I & O MANUAL INDIRECT HEX - ALLOW 18" FOR SERVICE ON ALL SIDES FLUE CONNECTION GAS INLET BOILER PUMP PRESSURE REDUCING VALVE / AUTO FILL VALVE EXPANSION TANK SYSTEM SENSOR LOCATION 1,000,000-1,500,000 BTU S TEMPERATURE AND PRESSURE GAUGE RELIEF VALVE CUPRO-NICKEL POOL HEAT EXCHANGER SKID MOUNTED ON STEEL FRAME CONDENSATE DRAIN IMG00196 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) 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 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. 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. 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. 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. 2
FIG.2_Low Voltage Connections A B SHIELD 1 ALARM 2 CONTACTS 3 RUN TIME 4 CONTACTS 5 LOUVER 6 PROVING 7 MODULE 2 8 FLOW SWITCH 9 MODULE 1 10 FLOW SWITCH 11 TANK 12 THERMOSTAT 13 R ENABLE 14 W LBL20052 REV B 15 SHIELD GND MOD BUS 16 A 17 B 18 SHIELD GND 19 (+) 20 (-) 0-10V INPUT 21 SYSTEM 22 SENSOR 23 OUT DOOR 24 SENSOR CASCADE 25 TANK 26 SENSOR 27 SHIELD GND 28 B 29 A 30 SHIELD GND SHIELD MODBUS COMMUNICATION BUS A B TO NEXT BOILER SHIELD SHIELD A B A B FROM PREVIOUS BOILER TO NEXT BOILER BUILDING MANAGEMENT SYSTEM 110v HIGH LIMIT SENSOR MODULE 2 MODULE 1 TANK THERMOSTAT ENABLING DEVICE SYSTEM SENSOR TANK SENSOR IMG00232 3
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. TABLE C Models 1.0-1.5 Total Amps 14.3 Figure 3 Line Voltage Field Wiring Connections 120V SUPPLY NEUTRAL W GROUND G LINE BK SERVICE SWITCH B DWH SPA 1 W L G DWH SPA 2 L W G B BK B B BK RLY20038 RLY20040 2 4 6 8 0 1 PUMP 1 W PUMP 2 W BK JUMPER BK IMG00493 4
Indirect Heat Exchanger Installation Instructions Heat exchangers should be installed downstream of the pumping and filtration equipment (FIG. 4). FIG. 4_Pumping and Filtration Equipment TO POOL CHLORINATOR (DOWNSTREAM) TOP VIEW Pool Water Chemistry It is essential that the instructions in this section and the Ryznar Stability Index and/or Calcium Stability Index are followed to prevent corrosion / erosion of the indirect heat exchanger: - Always keep ph within correct levels. The ideal pool ph should be kept 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 conditions 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 pipe work 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 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 highly acidic areas which can cause corrosion / erosion of the pool equipment. - Chlorinator should be installed downstream of the AQUAS. FILTRATION SYSTEM PUMP 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 for 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 FROM POOL IMG00197 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.6_Pressure Reducing Auto-Fill Valve PUSH CAP DOWN TO ACTIVATE FAST FILL FIG.5_pH Scale 7.4-7.6 5
FIG.7_Full Flow FROM POOL CPVC 110 LIMIT TO POOL IMG00198 NOTE: Model 1.5 shown for illustration purposes only. FIG.8_Bypass (if flow is greater than required by heat exchanger) CPVC FROM POOL FLOWMETER 110 VALVE THROTTLING LIMIT TO POOL RELIEF VALVE TEMPERATURE AND PRESSURE GAUGE IMG00199 NOTE: Model 1.5 shown for illustration purposes only. NOTICE NOTICE NOTICE Adjust valves to provide suggested flow per Table A on page 1. Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues. 6
FIG. 9_Bypass Multiple Units (if flow is greater than required by heat exchanger) 110 LIMIT (FOR EACH BOILER) VALVE THROTTLING (3X) FLOWMETER (3X) (OPTIONAL) RECOMMENDED ISOLATION VALVE FACTORY POOL RETURN SENSOR LOCATION CPVC PIPING IMG00200 NOTE: Model 1.5 shown for illustration purposes only. NOTICE Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. NOTICE System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues. 7
SYNC control module Use the control panel (FIG. 10) to set temperatures, operating conditions, and monitor boiler operation. FIG. 10_Control Panel AQUAS Pool Setup When the ON/OFF switch is turned to the ON position, the first screen displayed will be the Status Screen. The Deatils Screen and Main Menu Screen can be accessed by pressing the appropriate button. The SYNC is equipped with a SMART TOUCH control system. All menu options are accessed by touching the screen with your finger or a stylus. The Main Screen allows navigation to eight (8) additional screens which are used to set temperatures, operating conditions, and monitor boiler operation. These screens are as follows: Setup - Allows access to seven (7) other screens for the adjustment of the control parameters. Cascade - Shows the status of multiple boilers connected together in a cascade arrangement. Temps - Shows the temperatures measured by the individual sensors connected to the boiler. Burners - Shows the status of the two (2) independent burner systems used in the boiler. Building - Shows the information from a Building Integration System using Modbus Protocols. Graphs - Allows the selection of items to be graphed on a chart. History - Shows the operating and fault history of the two (2) control modules. Service Mode - Allows the installer to control the fan speed of the individual control modules for the purposes of combustion analysis. Service Mode will override all automatic heat demands, however, all safeties will remain intact. Navigation to the Main Screen can be accomplished by pressing the MAIN button at the bottom of the page. Reference the SYNC Service Manual for more information regarding the eight (8) accessible screens. Time - The time is displayed in the upper right-hand corner of the display. It is displayed in 24 hour format. Reference the night setback parameters in the SYNC Service Manual for information regarding adjusting the date and time. Status button - Pressing this button displays the Status Screen. This screen shows the current status of the SYNC boiler. Access Modes User The user can view all of the settings on the LCD screen. By entering the user password #0704, the user can adjust User Set Point, HW Boiler Output Set Point, Backlight Time and Backlight Brightness Settings. Installer Most parameters are available only to the installer, accessible by entering the installer access code #5309. 8
Cascade When multiple boilers are installed, they can be wired together in a cascade sequence. A maximum of eight boilers can be controlled from a single control. In this application one boiler would be designated as the Leader control and all others would be designated as Member controls. Once the Leader boiler receives a call for heat from the Enable input or 0-10 VDC input, the control will determine what the set point will be. A fixed temperature set point can be programmed into the control. If the water temperature at the system supply sensor is less than the set point + the turn-off offset - the off-on differential, then the control will initiate a call for heat on the Cascade (see the SYNC Service Manual for an explanation of the offset and differential). The Leader will energize the lead boiler on the Cascade. For a new startup this will be the Leader boiler. The boiler will fire at its ignition speed and will then modulate its firing rate to maintain the set point. If the first boiler reaches 100% of its firing rate, the Leader will calculate at what point the second boiler could fire at 10% of its firing rate. At this point, the Leader will fire the second boiler on the Cascade. For a new startup, this would be the first Member boiler. The boiler will fire at its ignition speed and will then modulate its firing rate to maintain the set point. If the set point still cannot be met, the Leader will continue firing more Members until either the heat demand is met or all boilers on the Cascade are firing. As the heat demand decreases, the last boiler on will modulate down to 10% of its firing rate. Once the demand for that boiler is zero, it will shut down. As the heat demand decreases further, the second to last boiler will modulate down and shut off. This will continue until the demand is satisfied and all boilers are shut off. Sequence of the cascade To equalize the run time of all boilers on the Cascade, the firing sequence will automatically be changed at set intervals. For the first 24 hours after initializing the Cascade, the sequence will be changed every hour. After that the sequence will be changed once every 24 hours. The switching on/off sequence will be as follows: If more than two boilers are on the Cascade, daisy chain the wiring from the Sequencing terminals on the second boiler to the Sequencing terminals on the third boiler, then from the third to the forth, and so on. The connections between boilers can be made in any order, regardless of the addresses of the boilers. Try to keep each cable as short as possible. TIME SWITCHING ON SEQUENCE START L-M1-M2-M3-M4-M5-M6-M7 1 hour M2-M3-M4-M5-M6-M7-L-M1 2 hours M4-M5-M6-M7-L-M1-M2-M3 Wiring of the Cascade When wiring the boilers for Cascade operation, select one boiler as the Leader boiler. The remaining boilers will be designated as Members. See Configuration of the Cascade for a detailed explanation of this procedure. Communication between the Leader boiler and the Member boilers is accomplished by using shielded, 2-wire twisted pair communication cable. Connect one of the twisted pair wires to terminal A on each of the Low Voltage Connection boards (FIG. 3), and the other wire of the twisted pair to terminal B on each of the Low Voltage Connection Boards. Connect the shield wires to one of the shield ground terminals on the Low Voltage Connection Boards. 9
Cascade Parameters Screen: Cascade Parameters The Cascade Screen allows access to four (4) parameters. Those parameters are as follows: Cascade Address - The boiler designated as the Leader should be programmed with address 0-1. All Member boilers require addresses from 2-3 through 14-15. The address must be different for each member. The addresses can be in any order, regardless of the order in which the boilers are wired together. This parameter can only be changed by the installer. The default address is 0-1. Cascade Off Differential - Sets how many degrees above set point the temperature has to go before the lead boiler will shut off. This parameter can only be changed by the installer. The temperature range of this parameter is 0 to 72 F. The default value is 10 F. Maximum Outlet Temperature - Sets the set point that individual boilers will attempt to achieve in a cascade. When a boiler is commanded to fire by the Leader, it will attempt to achieve this temperature at its outlet. The Leader will control the modulation of the last boiler to fire in order to hold the temperature at the system supply sensor to the user set point. If any of the boiler outlet temperatures reach the Maximum Outlet Temperature setting, the boiler will then modulate down on its own in order to keep its outlet temperature within the Maximum Outlet Temperature setting. Therefore, this parameter can be used to limit the outlet temperatures of all the boilers in a cascade. The default value is 160 F. Reference the SYNC Service Manual for additional information regarding changing parameters. Cascade Off/On Differential - Sets how many degrees below the turn off temperature (set point + Cascade Off Differential) the temperature has to go before the lead boiler will turn on. This parameter can only be changed by the installer. The temperature range of this parameter is 0 to 72 F. The default value is 20 F. 10
Stand alone Operation Access the Set Up Screen from the Main Menu Screen, then select Setpoints. The following options will be available for Standalone Operation. 1. User Set Point 2. Cascade OFF/ON differential 3. Cascade OFF differential 4. Maximum User Set Point To change parameters touch the hand icon on the screen and enter the installer code #5309. Proceed following the procedure below: > Parameter Change > Set Point > Apply > Next > Set Up > Save Then proceed to the Boiler Status Screen. Sequence of operation Cascade Multiple Units Together Access the Set Up Screen from the Main Menu Screen, then select Setpoints. The following options will be available for Cascade. 1. User Set Point 2. Cascade Address 3. Cascade OFF/ON differential 4. Cascade OFF differential 5. Maximum Outlet Temperature Note: This unit is equipped with two (2) independent, but synchronized combustion systems. The Heat Exchanger 1 combustion system will fire first. If the demand cannot be met by one (1) combustion system the same sequence of operation will be followed to bring the Heat Exchanger 2 combustion system online. 1. Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for a pool heating call, HW pump relay output for a HW call). 2. The control confirms that the low water cutoff and flow switch (optional) contacts are closed. 3. The control starts the blower and closes the louver contacts to begin the Pre-Purge cycle. 4. 5. 6. 7. 8. 9. 10. 11. The control confirms that the blower comes up to the desired speed, the flap valve opens, and the air pressure switch, gas pressure switch (optional), louver proving switch (optional), and blocked drain switch contacts close. Once the Pre-Purge cycle is complete, the control lowers the blower speed, initiates sparking of the ignition electrode, and opens the gas valve. After a short wait, the control stops sparking and checks for the presence of flame current through the spark and flame sense electrodes. If the control does not detect flame current, the control will lockout indefinitely, until the RESET button on the touch screen LCD is pressed. If the control detects flame current, the control will hold the blower speed constant for a few seconds to allow the flame to stabilize, then begin modulating the firing rate in order to maintain the controlling sensor to the desired set point temperature. If the current call for heat is for pool heating and an optional DHW call for heat becomes active, the control will turn on the HW pump relay output, then turn off the boiler pumps. It will then modulate the blower speed in order to maintain the outlet temperature to the desired DHW outlet set point temperature. If the first heat exchanger in the boiler is unable to maintain the desired set point temperature, the second heat exchanger in the boiler will be started, using much of the same sequences as described above. Once both heat exchangers are firing, the controls will work in synchronization to maintain the desired set point temperature. If the heat load should decrease sufficiently, the second heat exchanger will be shut down, much like the sequences described below. Once both the space heating and DHW calls for heat are satisified, the control will turn off the gas valve and begin the Post-Purge cycle. Any pumps that are running will begin their respective Pump Delay cycles. 12. At the end of the Post-Purge cycle, the louver contacts will open. 13. The control verifies that the blower stops running and the flap valve closes. 14. At the end of the Pump Delay cycle(s), the pump(s) will be turned off. 11
Pump Wiring Connections 1. Connect the 120 volt supply line (white wire) to terminal (1) and the black wire to terminal (2) (FIG. 3, on page 4). 2. Cut field-supplied wire to create a three-leg jumper. Connect one end to terminal (2), one end to terminal (8) and the remaining end to terminal (10) as shown in FIG. 3. 3. Cut field-supplied wire to create two additional wire lengths to make boiler pump connections. Connect the first wire from terminal (7) to Boiler Hex 1. Connect the second wire from terminal (9) to Boiler Hex 2 as shown in FIG. 3. 4. Connect the two white wires from the pumps (FIG 3) to the neutral line coming from the 120 volt supply line, terminal (1). 5. Make all necessary ground connections from the pumps to the terminal strip. Pump Relay Wiring Connections (Spa Only) 1. From the pump relay, connect terminals (3) and (4) on the terminal strip to terminal coils (0) and (1) on the terminal block base (see FIG. 3). 2. This relay contains two sets of contactors: terminal blocks (2) and (4) and terminal blocks (6) and (8). 3. Two pumps will be needed for DHW/Spa applications. Connect the first line from terminal block (2) to Pump 1. Run a separate wire from terminal block (8) to Pump 2. 4. Run the 110 volt service line (black wire) from terminal block (4), then repeat and run wire to terminal block (6). A switch should be installed before it goes to the Pump Relay. 5. Loop the white or neutral wire from both pumps back to the 110 volt power source. DHW/Spa Circulating Pump Field-supplied. The pump MUST be sized to meet the specified minimmum flow requirements. Consult the indirect boiler operating guide to determine flow characteristics for the selected product used. Refer to Section 5: Hydronic Piping in the SYNC Installation and Operation Manual for additional information on Near Boiler piping components. CONNECTOR (MSC2462) RELAY BASE (RLY20038) SCREW (BLT7038) Field Installation of Pump Relay (Spa Only) The Auxiliary heat exchanger kit contains all parts necessary to install the pump relay for Spa operation. Reference FIG. 11 to locate the pump relay on the back of the pool heater using the pre-drilled holes. 1. Using the two (2) kit-provided screws (BLT7038) mount the base (RLY20038) and relay (RLY20040) to the back panel of the unit. 2. Remove the single knockout on JKB60682. Secure the lower high voltage cover to the back panel of the unit using BLT2058. 3. Remove the cover on the field voltage line connection box to gain access. 4. Remove one of the knockouts from the connection box. Insert two (2) connectors (MSC2462) and two (2) conduits (MSC2459) into each part. 5. Cut two equal lengths from WRE7502 in the kit. Strip the wire and attach LUG7022 terminal, wire and fork 18-22 GA #6 to each end. Route the wire back through the assembled conduit. 6. Snap each end into place where the knockout has been removed In the high voltage line box, connect wires to terminals 3 & 4 for pump relay. Secure the open ends to the socket relay (RLY20040). 7. Attach connection points to terminals 0 & 1, then insert RLY20040 into RLY20038. Refer to FIG. 3 to properly wire Spa pumps. 8. Remove the two knockouts on the auxiliary high voltage junction box cover and insert the remaining two (2) connectors (MSC2462). 9. Use the remaining screws (BLT2058) to reattach the back jacket and replace the cover on the field voltage line box. Figure 11_Pump relay installation SCREW (BLT2056) PLASTIC CONDUIT (MSC2459) AUXILIARY HIGH VOLTAGE JUNCTION BOX COVER (JKB60683) AUXILIARY HIGH VOLTAGE JUNCTION BOX (JKB60682) RELAY SOCKET (RLY20040) Revision Notes: Revision A (ECO C09876) initial release. Revision B (ECO C10839) reflects the addition of the Line Voltage Connection section and Table C on page 2 as well as FIG. 3 on page 4. IMG00494 12
Auxiliary Heat Exchanger / Domestic Hot Water This system received factory installed auxiliary tappings for Domestic Hot Water (DHW) or Spa operation. The heat exchanger kits listed in Tables E and F include all the necessary parts to install the auxiliary heat exchanger in the field. Piping is not included with this package and should be field-supplied. Flow charts are provided in FIG. s 17 & 18 on page 16 so that a pump may be properly sized for the system. Use the connection points indicated for DHW operation on the boiler. Refer to Table E for boiler flow requirements. Reference FIG. 12 for an Auxiliary piping illustration. TABLE E - Spa Parameters Model 1.0 1.3 1.5 BTU/hr Input 100,000 130,000 150,000 Min HEX Flow (GPM) 32 37 42 DHW/Spa Connection Inlet 2" (Qty. 2) 2" (Qty. 2) 2" (Qty. 2) Outlet 3" 3" 3" Heat Exchanger(s) HEX30060 or HEX30061 HEX30061 HEX30061 TABLE F - Heat Exchanger Data Tube Sheet / Pool Side Flow Heat Exchanger Shell Pool Max Flow (GPM) Min Flow (GPM) HEX30060 1.25" 2" 127 50 HEX30061 2" 3" 330 93 FIG. 12_Auxiliary Piping for Spa RECOMMENDED ISOLATION VALVE CPVC FROM POOL 110 LIMIT RELIEF VALVE TO POOL TEMPERATURE AND PRESSURE GAUGE FACTORY POOL RETURN SENSOR LOCATION FACTORY SPA RETURN SENSOR LOCATION TO SPA 110 LIMIT IMG00441 NOTICE 13 FROM SPA Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
Hot Water Generator pump sizing The AQUAS has two (2) heat exchangers that require two (2) individual pumps for proper installation in the boiler loop and an additional two (2) pumps for the Hot Water Generator loop. Figure 14 Pump Configuration Hot Water Pump Head Loss = Ft. of Head for Heat Exchanger 1 (at required flow) + Ft. of Head for the Hot Water Generator (at 2 X the flow of Heat Exchanger 1) Example: FROM SYSTEM TO BOILER INLETS FROM SYSTEM TO BOILER INLETS Boiler: XP 1.5 A T of 30 requires a flow through each heat exchanger of 51 GPM. The heat exchanger head loss is 18 ft. of head (see Table 5A). Coupled with a Lochinvar Hot Water Generator with a 8-42 (diameter-length) tube bundle the calculated pressure drop is 1.2 Ft. of Head at 102 GPM. OK NO Hot Water Pump Head Loss = 18 Ft/Hd (51 GPM) + 1.2 Ft/Hd (102 GPM) = 19.2 Ft/Hd A pump will need to be selected to flow 51 GPM with a head loss of 19.2 Ft/Hd. Figure 13 Boiler Schematic TO SYSTEM FROM SYSTEM HEAT EXCHANGER 2 BOILER PUMP HEAT EXCHANGER 1 BOILER PUMP HOT WATER GENERATOR AIR COVER HEAT EXCHANGER 1 HOT WATER PUMP 51 GPM 102 GPM 102 GPM HEAT EXCHANGER 2 HOT WATER PUMP 51 GPM 14
Viewable and Changeable Control Parameters FIG. 15_Boiler Status Screen FIG. 16_Set Point Screen When the ON/OFF switch is turned to the ON position, the first screen visible on the LCD display will be the Status Screen. This screen displays the current status of the SYNC boiler. The following items can be viewed or interacted with on the Status Screen specifically for DHW/Spa operation: On/Off button - Pressing this button allows the boiler to be placed in either Manual Shutdown Mode or Standby Mode. Boiler Status - This line shows the current operating status of the SYNC boiler. Displayed items are as follows: HW Storage - The boiler has received a hot water generation/spa call. HW Pump Delay - The boiler has satisfied a hot water generation call and the hot water generator/spa pumps are running for a fixed time to remove any residual heat. HW Outlet Set Point Met - The outlet water temperature has exceeded the HW Generator/Spa Set Point parameter. Indirect HW Set Point - When a Hot Water Generation/Spa call for heat becomes active, the control will use the Indirect HW set point to determine the firing rate of the boiler based on the actual boiler outlet water temperature. This parameter can be changed by the user or the installer. The temperature range of this parameter is 50 to 190 F. The default value is 180 F. The Pumps Screen allows access to four (4) parameters. The following parameter deals specifically with DHW/Spa operation: HW Pump Delay - Sets the length of time the Hot Water Generation pumps (if connected) will run after a Hot Water Generation call has been satisfied. This parameter can only be changed by the installer. The time range for this parameter is 0 minutes to 40 minutes. The default time is 30 seconds. Reference the SYNC Service Manual for additional information about control parameters. The Set Point Screen allows access to 12 parameters. The following parameters deal specifically with DHW/Spa operation: Hot Water Tank Set Point - When a tank sensor is installed in a hot water storage tank, the hot water tank set point sets the target temperature of the water in the tank. This parameter can be changed by the user or the installer. The temperature range of this parameter is 60 to 185 F. The default value is 125 F. Hot Water Tank Differential - Sets how many degrees below the Hot Water Tank Set Point the hot water tank temperature must drop before the boiler will turn on. This parameter can only be changed by the installer. The temperature range for this parameter is 0 to 100 F. The default value is 5 F. 15
FIG. 17_Shell and Tube Sheet Flow HEX30060 2.00 Shell Side Flow HEX30060 4.00 Tube Sheet Flow HEX30060 1.75 3.50 1.50 3.00 1.25 2.50 PSI 1.00 PSI 2.00 0.75 SHELL SIDE FLOW 1.50 Tube Sheet Flow 0.50 1.00 0.25 0.50 0.00 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 FLOW 0.00 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 FLOW FIG. 18_Shell and Tube Sheet Flow HEX30061 PSI Shell Side Flow HEX30061 7 6.5 6 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 FLOW Shell Side Flow PSI Tube Sheet Flow HEX30061 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 85 95 105 115 125 135 145 155 165 175 185 195 205 215 225 235 FLOW Tube Sheet Flow Revision Notes: Revision A (ECO C09876) initial release. Revision B (ECO C10839) reflects the addition of the Line Voltage Connection section and Table C on page 2 as well as FIG. 3 on page 4. Revision C (ECO C11197) reflects the addition of pages 13-16 as well as information and images about DHW/Spa operation. 16 09/12 - Printed in U.S.A.