PoolPak ComPak AW Series Installation and operating instructions

© 2017 PoolPak LLC. All rights reserved.
Installation, Operation and
Maintenance
ComPak®R-410A
AW/HCD Series
RoofComPak®Series
HCD (High Capacity Dehumidifier)
AW (Air and Water)
Horizontal (H) and Vertical (V) Configurations
FORM #: SVW06-PCPIOM-20170808
SUPERCEDES: SVW06-PCPIOM-20150514
UPDATED: JUNE 2018

3491 Industrial Drive
York, Pennsylvania 17402 USA
800-959-7725 Fax [phone]
© 2017 PoolPak LLC. All rights reserved. DRAFT-SVW06-PCP-IOM-20170706
Table of Contents
IMPORTANT ................................................................................................................................ 7
Warning ....................................................................................................................................................7
Intended Users............................................................................................................................................7
SECTION I: INDOOR POOL DESIGN .............................................................................................. 8
Introduction ................................................................................................................................................8
Creating an ideal environment for indoor pool facilities ...................................................................................8
Operating Cost...........................................................................................................................................8
Application ................................................................................................................................................8
Moisture Loads ..........................................................................................................................................8
Effects of Moisture ......................................................................................................................................8
Indoor Air Quality.......................................................................................................................................9
Occupant Comfort ......................................................................................................................................9
Pool Water Chemistry ...............................................................................................................................10
SECTION II: PRINCIPLES, FUNCTIONS, AND FEATURES................................................................. 11
The Mechanical Dehumidification System..................................................................................................... 11
Principles of Operation .............................................................................................................................. 11
Automatic Control of Air Temperature and Humidity...................................................................................... 11
Room Dew Point Control............................................................................................................................. 12
ComPak Operation.................................................................................................................................... 12
CommandPak®Control System.................................................................................................................... 13
Overview ................................................................................................................................................. 13
Humidity Control....................................................................................................................................... 13
Cold Surface Temperature Humidity Reset ....................................................................................................14
Space Heating..........................................................................................................................................14
Networking Multiple Units .........................................................................................................................14
Space Cooling (Optional) ..........................................................................................................................14
Water Heating (Models AWV and AWH only) ............................................................................................. 14
Features and Options ................................................................................................................................15
Standard Items Factory Mounted................................................................................................................. 15
Standard Items Factory Supplied for Field Installation ....................................................................................15
System Options......................................................................................................................................... 15
RoofComPak®Series.................................................................................................................................. 16
Design Features ........................................................................................................................................16
Durable Construction .................................................................................................................................16
Rooftop Installation.................................................................................................................................... 16
Microprocessor Controller..........................................................................................................................16
Heating Packages .....................................................................................................................................16
Self-Contained Air-Cooled Condensing Section ............................................................................................ 16
Evaporator Coil Options ............................................................................................................................17
Electronically Commutated (EC) Fans ........................................................................................................... 17
Unique Outside Air System......................................................................................................................... 17
Cupronickel Water Heat Exchanger ............................................................................................................17
Technical Summary ................................................................................................................................... 18
Dimensional Data...................................................................................................................................... 18

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ComPak®Series IOM
SECTION III: PERFORMANCE AND SIZING................................................................................... 19
ComPak®Performance...............................................................................................................................19
ComPak®AW (AWV, AWH) Performance .................................................................................................... 19
ComPak®HCD (HCDV, HCDH) Performance ................................................................................................20
ComPak®Unit Dimensions ..........................................................................................................................21
ComPak®Horizontal Dimensions ................................................................................................................. 21
ComPak®Vertical Dimensions .....................................................................................................................22
ComPak®Outside Air Damper Size .............................................................................................................23
Hot Water Coil Capacities .........................................................................................................................24
Factory Refrigerant Charge ........................................................................................................................25
Remote Air-Cooled Condenser (ACC) Performance........................................................................................26
Electric Duct Heater...................................................................................................................................28
General Duct Heater Information ................................................................................................................28
Duct Heater Sizes......................................................................................................................................28
SECTION IV: INSTALLATION........................................................................................................ 29
PCP Installation .........................................................................................................................................29
Introduction ..............................................................................................................................................29
Handling..................................................................................................................................................30
Clearance ................................................................................................................................................ 31
Mounting of ComPak Units ......................................................................................................................... 31
Inspection................................................................................................................................................. 31
Power Supply............................................................................................................................................ 31
Control Wiring.......................................................................................................................................... 31
Condensate Piping .................................................................................................................................... 31
Curb Mounting .........................................................................................................................................32
Integral Gas Furnace Option (RoofComPak Only) .........................................................................................33
CPCS-PCP Controls Field Wiring.................................................................................................................34
Overview .................................................................................................................................................34
Remote Interface Unit (1) ............................................................................................................................34
Cold Surface Temperature Sensor (2)...........................................................................................................35
Economizer System (Optional) (3)................................................................................................................35
Outside Air Temperature Sensor (Economizer Option Only) (4).......................................................................36
Air Cooled Condenser (Optional) (5)...........................................................................................................36
Auxiliary Pool Water Heating System (AWH Model only*) (6)........................................................................37
Auxiliary Air Heating System (7) .................................................................................................................37
External Alarm System (8) ..........................................................................................................................37
Building Fire Control System (9)...................................................................................................................38
Return Air Sensor (10)................................................................................................................................38
Purge Mode Input (11)................................................................................................................................38
AC Proof Input (12)....................................................................................................................................38
Pool Water Temperature Sensor (13)............................................................................................................38
Pool Water Piping (AWH and AWV models only*) .......................................................................................40
Salt Water Pools ....................................................................................................................................... 41
Condensate Drains.................................................................................................................................... 41
Water Cooled Condenser ..........................................................................................................................42
Remote Air-Cooled Condenser Installation....................................................................................................42
Space and Location Requirements ...............................................................................................................42
Field Installed Piping..................................................................................................................................44

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SECTION V: OPERATION ............................................................................................................ 48
CPCS-PCP Configuration............................................................................................................................48
CPCS-PCP Remote Interface Unit .................................................................................................................48
Status Display...........................................................................................................................................48
Purge Mode Control Menu .........................................................................................................................51
Detailed Status Menu.................................................................................................................................52
CPCS-PCP Network Operation ...................................................................................................................54
Network Configuration ..............................................................................................................................54
CPCS-PCP Service.....................................................................................................................................56
Service Menu ...........................................................................................................................................56
I/O Configuration .....................................................................................................................................57
History..................................................................................................................................................... 61
Utilities.....................................................................................................................................................63
Startup.....................................................................................................................................................63
Pre-Start Checklist......................................................................................................................................63
Start-Up ...................................................................................................................................................64
Troubleshooting.........................................................................................................................................65
Data Log Retrieval .....................................................................................................................................67
Network Troubleshooting Guide .................................................................................................................68
Troubleshooting Guide...............................................................................................................................69
Maintenance ............................................................................................................................................70
Overview .................................................................................................................................................70
Daily Maintenance ....................................................................................................................................70
Monthly Maintenance................................................................................................................................70
Annual Maintenance .................................................................................................................................70
SECTION VI: WIRING ................................................................................................................. 71
Auxiliary Air & Pool Water Heater Connections for Multiple Unit Installation ....................................................71
Auxiliary Air & Pool Water Heater Connection for a Two Pool Installation........................................................72
Field Wiring .............................................................................................................................................73
Fire Control System Connection................................................................................................................... 74
Factory Wiring Diagrams...........................................................................................................................75

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ComPak®Series IOM
LIST OF TABLES
Table 1-1. Typical Pool Water & Air Temperature Set-Points ..............................................................................9
Table 1-2. Recommended Pool Water Chemistry ...........................................................................................10
Table 2-1. RoofComPak®Technical Data.......................................................................................................18
Table 3-1. ComPak®AW Performance Summary ........................................................................................... 19
Table 3-2. ComPak®HCD Performance Summary..........................................................................................20
Table 3-3. AW/HCD Horizontal Unit Overall Dimensions...............................................................................21
Table 3-4. AW/HCD Vertical Unit Overall Dimensions...................................................................................22
Table 3-5. ComPak®Outside Air Damper Size..............................................................................................23
Table 3-6. Hot Water Coil Capacities..........................................................................................................24
Table 3-7. Factory Refrigerant R410A Charge ..............................................................................................25
Table 3-8. Remote ACC Performance Chart..................................................................................................26
Table 4-1. Horizontal ComPak Curb Dimension.............................................................................................33
Table 4-2. R410A Charge for Air Cooled Condensers (lb.) .............................................................................46
Table 4-3. Refrigerant (R410A) Charge for Different Line Size.........................................................................47
Table 5-1. Solenoid Activation ....................................................................................................................65
Table 5-2. Pool Water Chemistry.................................................................................................................70
LIST OF FIGURE
Figure 2-1. ComPak®AW and HCD Typical Refrigerant System Schematic .......................................................13
Figure 2-2. PCP RoofComPak®Dimensions....................................................................................................18
Figure 3-1 AW/HCD Horizontal Unit Elevation and End Views........................................................................21
Figure 3-2. AW/HCD Vertical Unit Elevation and Plan Views ..........................................................................22
Figure 3-3. Air-Cooled Condenser (PoolPak®) - Isometric Views.......................................................................27
Figure 3-4. Air-Cooled Condenser (Bohn) - Elevation Views............................................................................27
Figure 3-5. Duct Heater..............................................................................................................................28
Figure 4-1. Typical ComPak®AWH Series System Layout................................................................................29
Figure 4-2. RP Lift Views .............................................................................................................................30
Figure 4-3. RoofComPak®Curb Assembly ....................................................................................................32
Figure 4-4. ComPak Horizontal Curb Assembly ............................................................................................33
Figure 4-5. Remote Interface Mounting Plate.................................................................................................34
Figure 4-6. Economizer Operation ..............................................................................................................35
Figure 4-7. Outside Air Sensor ....................................................................................................................36
Figure 4-8. PAC Unit Field Wiring ...............................................................................................................36
Figure 4-9. Installation of a Hot Water Coil 3-Way Valve ...............................................................................37
Figure 4-10. Field Wiring Schematic............................................................................................................39
Figure 4-11. Typical Pool Water Piping Diagram (AWH and AWV Model Only)*.............................................. 41
Figure 4-12. AWH and HCDH Condensate Trap ...........................................................................................42
Figure 4-13. Remote ACC Installation Around Walls or Obstructions ...............................................................43
Figure 4-14. Remote ACC Installation When Installing Multiple Units ...............................................................43
Figure 4-15. Remote ACC Installation When Installing Units in Pits...................................................................43
Figure 4-16. Remote ACC Installation When Installing Units Near Decorative Fences.........................................44
Figure 4-17. ACC Refrigerant Piping.............................................................................................................45
Figure 5-1. RIU Keypad ..............................................................................................................................48
Figure 5-2. Initial Startup Screen .................................................................................................................48
Figure 5-3. Status Screen 1 ........................................................................................................................48
Figure 5-4 Status Screen 4 .........................................................................................................................49

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Figure 5-6. Air Temperature Selection on the Set Points Menu.........................................................................50
Figure 5-7. Air Temperature Set Point Change Screen ....................................................................................50
Figure 5-8. Pool Temperature Set Point Change Screen .................................................................................. 51
Figure 5-9. Purge Mode Freeze Caution Screen ............................................................................................52
Figure 5-10. Detailed Status Menu...............................................................................................................52
Figure 5-11. Detailed Status Screen 2...........................................................................................................52
Figure 5-12. Detailed Status Screen 5 ..........................................................................................................53
Figure 5-13. Unit Present Screen..................................................................................................................54
Figure 5-14. Fault History Log screen ........................................................................................................... 61
Figure 5-15. Time and Date Screen..............................................................................................................63
Figure 5-16. Data Retrieval Using USB Key ...................................................................................................67
Figure 6-1. Auxiliary Air and Pool Water Heater Connections for Multiple Units................................................71
Figure 6-2. Auxiliary Air and Pool Water Heater Connections for Two Pool Installations.....................................72
Figure 6-3. Field Wiring Diagram................................................................................................................73
Figure 6-4. Fire Control System Connection .................................................................................................. 74
Figure 6-5. ComPak AW/HCD Main Schematic - Single Phase .......................................................................75
Figure 6-6. ComPak AW/HCD Main Schematic - Three Phase ........................................................................ 76
Figure 6-7. ComPak AW/HCD Point to Point Schematic - Single Phase, Vertical Unit ..........................................77
Figure 6-8. ComPak AW/HCD Point to Point Schematic - Three Phase, Vertical Unit...........................................78
Figure 6-9. ComPak AW/HCD Point to Point Schematic - Single Phase, Horizontal Unit......................................79
Figure 6-10. ComPak AW/HCD Point to Point Schematic - Three Phase, Horizontal Unit.....................................80
Figure 6-11. RoofComPak Factory Wiring Diagram........................................................................................81
Figure 6-12. ComPak and RoofComPak Startup Checklist ...............................................................................83

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ComPak®Series IOM
IMPORTANT
This product has been thoroughly tested before leaving the PoolPak factory.
However, please check at the earliest opportunity that the product has arrived in good condition and that no
damage occurred during shipping. If any damage is suspected, contact the carrier to file a claim.
If the product is to sit in storage for a length of time before installation, contact PoolPak Service department for
proper storage guidelines.
Warning
Only suitably qualified personnel who thoroughly understand the operation of this product and any associated
machinery should install, start-up or attempt maintenance of this product. Non-compliance with this warning may
result in personal injury or equipment damage.
PoolPak Service department must be contacted at least 2 weeks prior to equipment startup. A PoolPak authorized
service technician will perform startup and provide training for owner and site personnel.
PoolPak recommends that all troubleshooting, service, and maintenance be completed by an authorized service
technician for the best service experience with the equipment. If a labor or parts warranty claim is expected,
PoolPak service must be contacted before any work is to be performed. Refer to the standard ComPak warranty
for complete details.
Intended Users
This manual is to be made available to all persons who are required to install, operate or service the product
or any other associated operation. Please ensure that a copy of this manual is presented to the end customer.
Additional copies of this manual are available on request and on the PoolPak website, www.PoolPak.com.

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SECTION I: INDOOR POOL DESIGN
Introduction
Creating an ideal environment for indoor pool facilities
Indoor pool facilities are unlike any other structure in design, construction and maintenance requirements.
Humidity, air and water temperatures are especially difficult to control, and improper management usually results
in an uncomfortable environment, excessive operating costs and possibly serious structural damage. Effectively
controlling these special conditions require control hardware and control sequences specially engineered for
large commercial indoor pool applications. The PoolPak System utilizes an environmental control package
designed to meet all special needs of the indoor pool environment, while reducing energy usage and building
maintenance costs.
Operating Cost
Energy consumption is a direct function of the variables necessary to satisfy the occupant and protect the
facility. These variables include space heating and cooling, water heating, humidity removal and ventilation.
Maintaining ideal and precise environmental conditions has a fairly high cost of operation. And for a majority of
the indoor pools, regardless of geographic location, require water and space heating 70% to 90% of the year.
Application
Moisture Loads
An indoor swimming pool produces large quantities of water vapor through evaporation, which accounts for
roughly 95% of the pool water heat loss, making the water colder. This excessive humidity will form damaging
condensation unless removed from the building. In the past, the method of removing this water vapor was
by ventilating an otherwise energy efficient building, exhausting the humid air and the energy it contained.
Additional energy was used to bring in and heat the make-up air and to heat the pool water.
More cost effective technologies offer an alternative method adding heat exchangers and mechanical heat
recovery systems with many useful options. The ideal solution to removing the water vapor from the pool area is
to convert the latent (wet) heat contained in the moist air back into sensible (dry) heat, placing it back into the
pool water and air.
Effects of Moisture
Excess humidity in natatorium structures may be readily apparent as condensation on cool surfaces such as
windows and outside doors, the growth of mildew or mold, and, when coupled with poor pool chemistry, the
accelerated corrosion of metals. In its less obvious forms, moisture may penetrate walls and ceilings and cause
rot that becomes noticeable only when large scale structural failure occurs. Humidity levels are also a major
factor in the comfort of pool users.

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ComPak®Series IOM
POOL TYPE WATER TEMP (°F) AIR TEMP (°F) ROOM RH %
Recreational Pool 80 to 85 Water Temp + 2 55 to 60
Therapy Pool 86 to 92 86155 to 60
Whirlpools 99 to 104 86155 to 60
Table 1-1. Typical Pool Water & Air Temperature Set-Points
1Normally max 86°F to minimize overheating of occupants
Indoor Air Quality
Pools and water parks with water features have a higher evaporation rate than a standard pool because of
the increased water surface area. Chloramines (See Pool Water Chemistry below), which are present in the
water, become more concentrated in the air as the “water to air” interactions increase, affecting the indoor air
quality. A strong “chlorine” odor is an indicator of poor pool water chemistry, and is generally offensive to the
occupants. Higher levels of chloramines can cause skin/eye irritation and respiratory problems commonly known
as “lifeguard lung”.
Most poolrooms are designed with a minimum ventilation rate to dilute the airborne pollutants generated from
the chemical interactions in the pool water. Typically these rates are based on ASHRAE standard 62.1 and
dictated by local codes at about 0.5 CFM/ square foot of pool and deck area, but depending on the pool
water chemistry the ventilation rate may not always be adequate for good poolroom indoor air quality.
However, increasing ventilation rates can significantly add to the cost of operation. Including energy
conservation strategies such as heat recovery, airflow measurement and CO2 based control help control costs
while improving indoor air quality.
Depending on the geographic location and season of the year, treating the outside air has a direct effect on
energy consumption. Some facilities prefer higher than minimum ventilation rates, up to 100% of OA,
to maximize indoor air quality, but the cost of treating this air can be significant.
Occupant Comfort
Occupant comfort in a natatorium is easy to understand. If you ever swam in an outdoor pool on a cold,
windy day, or exited a pool in a dry, desert location--you will probably notice an immediate chill. The opposite
is true where high humidity is not adequately controlled either through ventilation or by mechanical means.
The moisture level can reach such a state where it is oppressive or stuffy. Common complaints are difficulty in
breathing and the room being perceived to be warmer than the actual dry bulb temperature would suggest.
Regardless of the source of discomfort, users will not enjoy the facility if water/air temperatures and humidity
levels are not within a narrow range. Ideal water temperature is around 82° with the air temperature about 2
degrees F higher to prevent chilling when exiting the pool and to minimize evaporation from the pool surface.
Here are some recommended temperatures for poolrooms, which can be adjusted to meet specific needs of
bathers. In general, “active” poolrooms are maintained at lower temperature ranges so the users don’t overheat,
warmer temperatures are more common for seniors or children or less active pools.
The desirable humidity range is generally between 50% and 60%--greater than 60% creates a sticky feeling
and/or difficult breathing, and low humidity results in evaporative cooling on the bather’s skin, resulting in a
chill.
Poor air movement caused by improper duct placement within the poolroom will also lead to occupant
discomfort. Excessive supply air blowing on bathers can create drafts, while uneven air distribution may create
stagnant zones within the space.

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POOL SPA
IDEAL MIN MAX IDEAL MIN MAX
Total Chlorine (ppm) 1.0 - 3.0 1 3 3.0 - 5.0 110
Free Chlorine (ppm) 1.0 - 3.0 1 3 3.0 - 5.0 110
Combined Chlorine (ppm) 0 0 0.3 0 0 0.3
Bromine (ppm) if applicable 2.0 - 4.0 2 4 3.0 - 5.0 210
pH 7.4 - 7.6 7.2 7.8 7.4 - 7.6 7.2 7.8
Total Alkalinity (ppm) 80 - 100 80 180 80 - 100 60 180
TDS (ppm) 1000 - 2000 300 3000 1000 - 2000 300 3000
Calcium Hardness (ppm) 200 - 400 150 1000 200 - 400 150 1000
Calcium Acid (ppm) 30 - 50 10 100 30 - 50 10 100
Table 1-2. Recommended Pool Water Chemistry
Pool Water Chemistry
Water chemistry in swimming pools is critical for the health of the bathers and the condition of the enclosure and
components. An enclosure with poor water chemistry has a noticeable “chlorine” smell, which is an indication of
high chloramines in the air. Not only does this have an effect on the water, but it affects the bathers and the air
they breathe.
Dehumidification systems are not designed to remove the effects of incorrect pool water chemistry.
Dehumidification/ventilation equipment is not designed to remedy the effects of poor pool chemistry, but is
designed to deliver prescribed ventilation to manage smaller amounts of pollutants generated from normal pool
activity. Pool water chemistry is a part of daily maintenance and it is recommended that the users follow the
current National Spa and Pool Institute standards.
For more information, review the Controlling Chloramines with Proper Chlorine Management chapter in the
Indoor Pool Water Chemistry publication at the online PoolPak®Educational Library.