PoolPak R-410A AW Series User manual

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PoolComPakTM (PCP)
RoofPak (AWH/ HCDH only)
POOLCOMPAK R-410A
AW/HCD SERIES
ROOFPAK SERIES
HCD (High Capacity Dehumidier)
AW (Air and Water)
Horizontal (H) and Vertical (V) Congurations
Engineering Guide
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Packaged Natatorium Environment Control System

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3491 Industrial Drive . York, PA 17402 . USA . 800-959-7725 . Fax [phone]
for more information: www.poolpak.com
The Leader in Indoor Pool Dehumidication
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TABLE OF CONTENTS
SECTION I: INDOOR POOL DESIGN ............................................................................................................................................ 1
Introduction .................................................................................................................................................................................. 1
Creating an ideal environment for indoor pool facilities............................................................................................................ 1
Operating Cost ......................................................................................................................................................................... 1
Application ................................................................................................................................................................................... 1
Moisture Loads ........................................................................................................................................................................ 1
Effects of Moisture ................................................................................................................................................................... 1
Indoor Air Quality ...................................................................................................................................................................... 1
Occupant Comfort .................................................................................................................................................................... 2
Pool Water Chemistry ............................................................................................................................................................. 2
Equipment Choices ...................................................................................................................................................................... 3
Overview .................................................................................................................................................................................. 3
Ventilation with Heating ............................................................................................................................................................ 3
Ventilation with Heating and Energy Recovery ........................................................................................................................ 3
Mechanical Dehumidication.................................................................................................................................................... 3
Hybrids ..................................................................................................................................................................................... 4
Other Technologies .................................................................................................................................................................. 4
Room Air Distribution ................................................................................................................................................................... 4
Airside Design .......................................................................................................................................................................... 4
Supply Air.............................................................................................................................................................................. 4
Return Air .............................................................................................................................................................................. 6
Ductwork Design................................................................................................................................................................... 6
Air Distribution ...................................................................................................................................................................... 6
Other Airside Considerations ................................................................................................................................................ 7
SECTION II: PRINCIPLES, FUNCTIONS, AND FEATURES .......................................................................................................... 8
The Mechanical Dehumidication System ................................................................................................................................... 8
Principles of Operation ............................................................................................................................................................. 8
Automatic Control of Air Temperature and Humidity ................................................................................................................ 8
Room Dew Point Control .......................................................................................................................................................... 9
PoolComPak Operation............................................................................................................................................................ 9
ECC-PCP Control System ........................................................................................................................................................... 10
Overview .................................................................................................................................................................................. 10
Humidity Control ....................................................................................................................................................................... 10
Cold Surface Temperature Humidity Reset .............................................................................................................................. 10
Space Heating .......................................................................................................................................................................... 10
Networking Multiple Units ........................................................................................................................................................ 11
Space Cooling (Optional) ......................................................................................................................................................... 11
Water Heating (Models AWV and AWH only) ........................................................................................................................... 11
Features and Options .................................................................................................................................................................. 11
Standard Items Factory Mounted ............................................................................................................................................. 11
Standard Items factory Supplied for Field Installation .............................................................................................................. 11
System Options ........................................................................................................................................................................ 11
RoofPak System....................................................................................................................................................................... 12
PoolComPak™ Dehumidication Systems Selection............................................................................................................... 12
Overview ............................................................................................................................................................................... 12
Available Congurations ....................................................................................................................................................... 12
Typical AW Series Applications ............................................................................................................................................. 12
Typical Non-Pool HCD Series Applications .......................................................................................................................... 12
Unit Selection software program........................................................................................................................................... 12
RoofPak Series (HCDH/AWH) ..................................................................................................................................................... 13
Design Features ....................................................................................................................................................................... 13
Durable Construction ............................................................................................................................................................ 13
Rooftop Installation ............................................................................................................................................................... 13
Microprocessor Controller..................................................................................................................................................... 13
Heating Packages................................................................................................................................................................. 13
Self-Contained Air-Cooled Condensing Section ................................................................................................................... 13
Evaporator Coil Options........................................................................................................................................................ 13
Totally Enclosed, Fan Cooled (TEFC) Motors ..................................................................................................................... 14
Unique Outside Air System ................................................................................................................................................... 14

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Housed Blower ..................................................................................................................................................................... 14
Cupronickel Water Heat Exchanger ..................................................................................................................................... 14
Technical Summary .................................................................................................................................................................. 15
Dimensional Data ..................................................................................................................................................................... 15
RoofPak Weights ...................................................................................................................................................................... 15
SECTION III: PERFORMANCE AND SIZING ................................................................................................................................. 16
PoolComPak™ Performance ................................................................................................................................................... 16
PoolComPak™ AW (AWV, AWH) Performance .................................................................................................................... 16
PoolComPak™ HCD (HCDV, HCDH) Performance ............................................................................................................. 17
PoolComPak Unit Dimensions ................................................................................................................................................. 18
PoolComPak™ Horizontal Dimensions ............................................................................................................................... 18
PoolComPak™ Vertical Dimensions..................................................................................................................................... 19
Hot Water Coil Capacities ........................................................................................................................................................ 20
PoolComPak Outside Air Damper Size .................................................................................................................................... 21
Refrigerant................................................................................................................................................................................ 22
Remote Air-Cooled Condenser (ACC) ..................................................................................................................................... 23
Electric Duct Heater ................................................................................................................................................................. 25
SECTION IV: INSTALLATION ......................................................................................................................................................... 26
PCP Installation ........................................................................................................................................................................... 26
Introduction............................................................................................................................................................................... 26
Unit/Facility Interface ................................................................................................................................................................ 26
Handling ................................................................................................................................................................................... 27
Clearance ................................................................................................................................................................................. 27
Mounting of PoolComPak Units ............................................................................................................................................... 27
Inspection ................................................................................................................................................................................. 27
Power Supply ........................................................................................................................................................................... 27
Control Wiring........................................................................................................................................................................... 27
Condensate Piping ................................................................................................................................................................... 27
Curb Mounting .......................................................................................................................................................................... 28
Integral Gas Furnace Option (RoofPak Only) .......................................................................................................................... 29
ECC-PCP Controls Field Wiring .................................................................................................................................................. 30
Overview .................................................................................................................................................................................. 30
Remote Interface Unit (1) ......................................................................................................................................................... 30
Cold Surface Temperature Sensor (2) ...................................................................................................................................... 31
Economizer System (Optional) (3) ........................................................................................................................................... 31
Outside Air Temperature Sensor (Economizer Option Only) (4) .............................................................................................. 32
Air Cooled Condenser (Optional) (5) ........................................................................................................................................ 32
Auxiliary Pool Water Heating System (AWH Model only*) (6) .................................................................................................. 33
Auxiliary Air Heating System (7) ............................................................................................................................................... 33
External Alarm System (8)........................................................................................................................................................ 33
Building Fire Control System (9) .............................................................................................................................................. 34
Return Air Sensor (10).............................................................................................................................................................. 34
Purge Mode Input (11) .............................................................................................................................................................. 34
AC Proof Input (12) .................................................................................................................................................................. 34
Pool Water Temperature Sensor (13) ....................................................................................................................................... 34
Pool Water Piping (AWH and AWV models only*) ....................................................................................................................... 35
Condensate Drains ...................................................................................................................................................................... 36
Water Cooled Condenser ............................................................................................................................................................ 37
Remote Air-Cooled Condenser .................................................................................................................................................... 37
Space and Location Requirements .......................................................................................................................................... 37
Walls or Obstructions ............................................................................................................................................................ 37
Multiple Units ........................................................................................................................................................................ 38
Units in Pits ........................................................................................................................................................................... 38
Decorative Fences ................................................................................................................................................................ 39
Field Installed PIPING .............................................................................................................................................................. 39
Piping Guidelines .................................................................................................................................................................. 39
Materials: ........................................................................................................................................................................... 39
Sizing: ............................................................................................................................................................................... 40
Refrigerant and Oil Charging: ........................................................................................................................................... 41
Sample Charging Calculation:........................................................................................................................................... 41

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SECTION V: OPERATION .............................................................................................................................................................. 43
ECC-PCP Remote Interface Unit ................................................................................................................................................. 43
Status Display .......................................................................................................................................................................... 43
Set Point Change Menu ........................................................................................................................................................... 44
Air Temperature .................................................................................................................................................................... 44
Relative Humidity .................................................................................................................................................................. 44
Pool Temperature ................................................................................................................................................................. 44
Recommendations ................................................................................................................................................................ 44
Purge Mode Control Menu ....................................................................................................................................................... 45
Detailed Status Menu ............................................................................................................................................................... 45
ECC-PCP Network Operation ...................................................................................................................................................... 46
Network Conguration .............................................................................................................................................................. 46
Pool Water Temperature Control .......................................................................................................................................... 46
Staged Dehumidication Control .......................................................................................................................................... 46
Dehumidication Stage 2 Offset ........................................................................................................................................... 46
Enable Network Control ........................................................................................................................................................ 46
Changing Set Points ............................................................................................................................................................. 47
ECC-PCP Service ........................................................................................................................................................................ 47
Service Menu ........................................................................................................................................................................... 47
I/O Conguration ...................................................................................................................................................................... 47
Digital Inputs ......................................................................................................................................................................... 47
Digital Outputs ...................................................................................................................................................................... 47
Analog Inputs ........................................................................................................................................................................ 48
Unit Conguration .................................................................................................................................................................... 48
Installed Options ................................................................................................................................................................... 48
Aux Air Heating ................................................................................................................................................................. 48
Aux Water Heating ............................................................................................................................................................ 48
Temperature Ctrl ............................................................................................................................................................... 48
Humidity Control................................................................................................................................................................ 49
BAS Interface ........................................................................................................................................................................... 49
Multi-Unit Network .................................................................................................................................................................... 49
Compressor .............................................................................................................................................................................. 49
Economizer .............................................................................................................................................................................. 49
History ...................................................................................................................................................................................... 49
Manual Mode............................................................................................................................................................................ 49
Utilities ...................................................................................................................................................................................... 49
Maintenance ................................................................................................................................................................................ 50
Overview .................................................................................................................................................................................. 50
Daily Maintenance .................................................................................................................................................................... 50
Monthly Maintenance ............................................................................................................................................................... 50
Annual Maintenance................................................................................................................................................................. 50
SECTION VI: WIRING ..................................................................................................................................................................... 51
Auxiliary Air & Pool Water Heater Connections for Multiple Unit Installation ........................................................................... 51
Auxiliary Air & Pool Water Heater Connection for a Two Pool Installation ............................................................................... 52
Field Wiring .............................................................................................................................................................................. 53
Fire Control System Connection .............................................................................................................................................. 54

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LIST OF FIGURES
Figure 1-1. Perimeter Air Distribution ........................................................................................................................................... 5
Figure 1-2. Overhead Air Distribution........................................................................................................................................... 5
Figure 1-3. Below Grade Air Distribution...................................................................................................................................... 5
Figure 1-4. Supply Air Proportions ............................................................................................................................................... 6
Figure 2-1. PoolComPak™ AW and HCD Typical Refrigerant System Schematic ...................................................................... 9
Figure 2-2. PCP RoofPak Dimensions ......................................................................................................................................... 15
Figure 3-1 AW/HCD Horizontal Unit Elevation and End Views .................................................................................................... 18
Figure 3-2. AW/HCD Vertical Unit Elevation and Plan Views....................................................................................................... 19
Figure 3-3. Air-Cooled Condenser (PoolPak) - Isometric Views .................................................................................................. 24
Figure 3-4. Air-Cooled Condenser (Bohn) - Elevation Views ....................................................................................................... 24
Figure 3-5. Duct Heater ............................................................................................................................................................... 25
Figure 4-1. Typical PoolComPak™ AWH Series System Layout ................................................................................................. 26
Figure 4-2. PoolComPak™ Curb Assembly ................................................................................................................................. 28
Figure 4-3. Remote Interface Mounting Plate .............................................................................................................................. 30
Figure 4-4. Economizer Operation ............................................................................................................................................... 31
Figure 4-5. Outside Air Sensor..................................................................................................................................................... 32
Figure 4-6. PAC Unit Field Wiring ................................................................................................................................................ 33
Figure 4-7. Installation of a Hot Water Coil 3-Way Valve ............................................................................................................. 34
Figure 4-8. Typical Pool Water Piping Diagram (AWH and AWV Model Only)* ........................................................................... 36
Figure 4-9. AWH and HCDH Condensate Trap ........................................................................................................................... 37
Figure 4-10. Remote ACC Installation Around Walls or Obstructions .......................................................................................... 38
Figure 4-11. Remote ACC Installation When Installing Multiple Units .........................................................................................38
Figure 4-12. Remote ACC Installation When Installing Units in Pits ............................................................................................ 39
Figure 4-13. Remote ACC Installation When Installing Units Near Decorative Fences ............................................................... 39
Figure 4-14. ACC Refrigerant Piping ........................................................................................................................................... 42
Figure 5-1. RIU Keypad ............................................................................................................................................................... 43
Figure 5-2. Status Screen 1 ......................................................................................................................................................... 43
Figure 6-1. Auxiliary Air and Pool Water Heater Connections for Multiple Units .......................................................................... 51
Figure 6-2. Auxiliary Air and Pool Water Heater Connections for Two Pool Installations ............................................................ 52
Figure 6-3. Field Wiring Diagram ................................................................................................................................................. 53
Figure 6-4. Fire Control System Connection................................................................................................................................ 54
LIST OF TABLES
Table 1-1. Typical Pool Water & Air Temperature Set-Points ....................................................................................................... 2
Table 1-2. Recommended Pool Water Chemistry ........................................................................................................................ 3
Table 2-1. RoofPak Technical Data .............................................................................................................................................. 15
Table 2-2. RoofPak Weights ........................................................................................................................................................ 15
Table 3-1. PoolComPak™ AW Performance Summary ............................................................................................................... 16
Table 3-2. PoolComPak™ HCD Performance Summary ............................................................................................................. 17
Table 3-3. AW/HCD Horizontal Unit Overall Dimensions ............................................................................................................. 18
Table 3-4. AW/HCD Vertical Unit Overall Dimensions ................................................................................................................. 19
Table 3-5. Hot Water Coil Capacities ........................................................................................................................................... 20
Table 3-6. PoolComPak™ Outside Air Damper Size ................................................................................................................... 21
Table 3-7. Factory Refrigerant R410A Charge ............................................................................................................................ 22
Table 3-8. Remote ACC Performance Chart ................................................................................................................................ 23
Table 3-9. Duct Sizes ................................................................................................................................................................... 25
Table 4-1. Horizontal PoolComPak™ Curb Dimensions .............................................................................................................. 29
Table 4-2. R410A Charge for Air Cooled Condensers (lb.) .......................................................................................................... 41
Table 5-1. Pool Water Chemistry ................................................................................................................................................. 50

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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 difcult 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 efcient 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.
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 per 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.

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However, increasing ventilation rates can signicantly add to the cost of operation. Including energy conservation
strategies such as heat recovery, airow 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 signicant.
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 difculty 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 specic 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
difcult 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.
Table 1-1. Typical Pool Water & Air Temperature Set-Points
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.
Dehumidication systems are not designed to remove the effects of incorrect pool water chemistry. Dehumidication/
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 Controling Chloramines with Proper Chlorine Management chapter in the Indoor Pool
Water Chemistry publication in the online PoolPak™ Educational Library.
Section I: Indoor Pool Design
Typical Pool Water & Air Temperature Set-Points
Pool Type Water Temp. °F Air Temp. °F Room RH %
Recreational Pools 80-85 Water Temp + 2 55-60
Therapy Pools 86-92 86155-60
Whirlpools 99-104 86155-60
1 Normally max 86°F to minimize overheating of occupants

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Table 1-2. Recommended Pool Water Chemistry
EQUIPMENT CHOICES
OVERVIEW
There are several methods for controlling humidity, temperature and ventilation in poolrooms. Each method offers some
level of control, but there can be signicant differences in rst cost and operating cost of each method. Geographic
location, degree of comfort, unit cost and operational cost must be evaluated in the selection of the correct system.
VENTILATION WITH HEATING
• Moisture removal is accomplished through the dilution with dryer outside air
• High cost of operation (air reheating)
• Lowest rst cost
• No opportunity to recover energy in the exhaust airstream
• No opportunity to recover energy into the pool water
• No integral cooling capability
• Summer space conditions can be unbearably hot and humid
VENTILATION WITH HEATING AND ENERGY RECOVERY
• Moisture removal is accomplished through the dilution with dryer outside air
• Signicant heat recovery from exhaust air stream
• Cost-effective method but with modest operating cost
• Performance limitations in humid areas or during summer peaks
• No opportunity to recover energy into the pool water
• No integral cooling capability
MECHANICAL DEHUMIDIFICATION
• Moisture removal is accomplished through mechanical refrigeration
• Signicant heat recovery using “heat pump” technology
• Recovers the most energy from the exhaust airstream
• Offers an opportunity to recover energy into the supply airstream
• Offers an opportunity to recover energy into the pool water
• Higher rst cost with lower operating cost
• No performance limitations based on location
• Tightest control of setpoint conditions
• Integral cooling capability
• Can be integrated to include appropriate ventilation strategies
Section I: Indoor Pool Design
Pool Spa
Ideal Min Max Ideal Min Max
Total Chlorine (ppm) 1.0 - 3.0 1 3 3.0 - 5.0 1 10
Free Chlorine (ppm) 1.0 - 3.0 1 3 3.0 - 5.0 1 10
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 2 10
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

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HYBRIDS
• Combines various technologies to increase efciency and capability
• Utilizes ventilation as primary dehumidication method
• Switches to heat pump method when conditions require better environmental control
OTHER TECHNOLOGIES
Desiccant technology can be adapted to provide super dry air which is injected into the poolroom to dilute the moisture
load. The regeneration phase of the desiccant is typically driven by waste heat from refrigeration cycle or other fossil
fuel.
Wheels are sometimes considered because of their wide acceptance as heat recovery devices. Latent or Enthalpy wheels
are not suitable for pools, but sensible wheels may have application.
ROOM AIR DISTRIBUTION
All PoolPak™ models provide continuous air recirculation, and with a good air distribution system, will promote
uniform space conditions. To remove the required moisture and maintain controlled conditions, it is essential that there
be adequate air movement and distribution in the natatorium. The unit must remove the humid air from the pool area
and discharge the dehumidied air back into it. The supply air should be distributed over areas subject to condensation
(windows, outside walls, support trusses, skylights, etc.).
AIRSIDE DESIGN
The supply air volume and external static pressure capability of the fan is given for each model in the Performance
Section. It is recommended that an experienced engineering or mechanical contracting rm do the design, sizing and
layout of the duct system.
The recommended volume of supply air should provide three to eight air changes an hour. However, in larger waterparks
or spaces with high sensible heat gain, higher airows may be appropriate. Lower air volumes require more care to avoid
short cycling the air between the return and supply, air stratication and pockets of high humidity.
The most even control of space conditions occurs with proper air distribution and a proper air ow rate. This provides
space control without excessive loading and unloading of refrigerant-based dehumidication equipment.
Supply Air
After dehumidication, dry air is supplied back to the room. Supply air should be distributed from ducting around the
perimeter (see Figure 1-1) of the space. The two options for perimeter supply air distribution are overhead (see Figure
1-2) or below grade (see Figure 1-3).
Section I: Indoor Pool Design

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Figure 1-1. Perimeter Air Distribution
ALL_AirDistributionPerimeter_20131220.eps
The warm, dry air should be directed over outside walls, windows and other surfaces susceptible to condensation, or it
can be directed down the center of the room blowing air toward the surfaces prone to have condensation. Supply ducts
should be as short and with as few turns as possible. Use turning vanes to minimize air noise and static pressure drop.
Recommended maximum supply duct air velocity is 1000 FPM. The recommended velocity from diffusers is 300 to
500 FPM. Air velocities in ducts should be kept as low as is reasonable to avoid excessive noise in the ducts. In multiple
unit installations, supply air from each unit may go into a common supply duct or into a plenum. A supply air duct
collar is provided at the fan outlet. The duct should be attached to this with a exible connection to minimize vibration
transmission.
Sky Light
ALL_AirDistributionDown_20131220.eps ALL_AirDistributionUp_20131220.eps
Figure 1-2. Overhead Air Distribution
SUPPLY AIR BLOWING
DOWN FROM SOFFIT DUCTS
COVERING WINDOWS AND
MOISTURE-EXPOSED AREAS
SUPPLY AIR
TO SKYLIGHTS
POOLPAK
DEHUMIDIFICATION
SYSTEM
RETURN AIR
Figure 1-3. Below Grade Air Distribution
Section I: Indoor Pool Design
BELOW GRADE DUCTING CEILING DUCTING
RETURN AIR
SUPPLY AIR
TO SKYLIGHTS
POOLPAK
DEHUMIDIFICATION
SYSTEM
SUPPLY AIR BLOWING UP
FROM BELOW-GRADE
DUCTS COVERING WINDOWS
AND MOISTURE-EXPOSED
AREAS
SUPPLY AIR BLOWING
DOWN FROM SOFFIT DUCTS
COVERING WINDOWS AND
MOISTURE-EXPOSED AREAS
SUPPLY AIR
TO SKYLIGHTS
POOLPAK
DEHUMIDIFICATION
SYSTEM
RETURN AIR

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Return Air
The unit will operate most efciently in a natatorium where the supply and return openings are placed diagonally
opposite each other. All ducting should be done in accordance with acceptable practices. Return air ducts in the section
just prior to entering the unit return air opening, and elbows in both the return and supply air ducts must comply with the
guidelines set forth in SMACNA HVAC Duct Construction Standards Metal and Flexible – Third Edition, Chapter 4.
Ductwork Design
All supply and return duct work to the unit should be installed such that no condensate occurs in the duct work. Duct
turns and transitions must be made carefully to keep friction losses to a minimum. Duct elbows should contain splitters
or turning vanes and avoid short radius ttings.
Duct work that is connected to the fan discharge should run in a straight line with proper transitions, and minimum
distances to elbows as recommended by SMACNA and should not be reduced in cross-sectional area. Duct turns should
be in the same direction as fan rotation. Never deadhead the fan discharge into the at side of a plenum.
Duct work attached to the PoolPak™ unit return air connection must be done in accordance with SMACNA
recommended standards and /or generally accepted industry practice.
Supply and return duct work should have all seams sealed before applying insulation to the exterior of the duct work.
The insulation’s seams must be sealed, wrapped, and mastic coated. Use of pre-insulated duct work (interior) is
acceptable if it meets local codes; however, all seams must be sealed prior to startup.
Air Distribution
Supply outlets and return grilles should be carefully placed to avoid short-circuiting in the space. Short-circuiting
creates stagnant areas where humidity and temperatures may build up to undesirable levels, reducing the effectiveness
of the PoolPak™ System. Return grilles can be placed high in the space to reduce return ductwork, however removal of
Chloramines from the occupied area has become much more of a design consideration and so low returns are favored by
poolroom designers.
Supply air should be directed 45 degrees up and down (most of the air will be directed downward) toward exterior walls,
windows, skylights, and other areas where stagnant conditions could cause humidity buildup and condensation problems
or drafts. The end result of the supply air ducts is to wash the surfaces of the pool room that are prone to condensation
with the warm, dry supply air.
Figure 1-4. Supply Air Proportions
20% OF SUPPL
Y
AIR DIRECTED
ALONG CEILING
80% OF SUPPLY
AIR DIRECTED
DOWN WALLS
WINDOW
SURFACE
12”
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Section I: Indoor Pool Design

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Diffusers for supply ducts located overhead (as opposed to under the deck) must be sized such that the supply air will be
thrown all the way to the deck and wash the entire wall surface from supply duct to the oor.
As a rule, directing the supply air at or across the pool surface increases the evaporation rate. To control the buildup of
chloramines at the surface of the pool, some air may be directed at the pool surface. Supply outlets should not discharge
directly onto surfaces where drafts may be created that will blow on swimmers walking along the edges of the pool.
Spectators should have supply air directed toward their faces.
The outside air intake and exhaust may have rain hoods if the unit is mounted outdoors. Rain hood locations are
illustrated on the unit arrangement drawings. The intake and exhaust should be screened to prevent the entrance of
foreign matter and arranged to avoid recirculation of exhaust and outside air. Also, when auxiliary gas heat is selected (in
an outside installation), a combustion air louver or rain hood is provided.
Ductwork connections over 5 feet long must be supported to avoid damage to unit. Short Flexible connections of rubber
or canvas can be made between the return duct and the unit to eliminate vibration transmission through the duct.
PoolPak™ International does not recommend the use of equipment rooms or locker rooms as return or supply air
plenums due to the potential of corrosion for components installed in the room. The return air duct should always
connect the pool enclosure to the return air plenum collar of the PoolPak™ unit(s).
Other Airside Considerations
A hot water, electric or gas duct heater may be installed in the supply duct to provide auxiliary space heating. Be sure
that the additional air pressure drop across the heater is accounted for in the unit fan selection. These heating components
must be designed for use in swimming pool environments.
Maintain the poolroom at a slightly negative pressure. This will minimize moisture and chemical odor migration to other
spaces. The exhaust fan should be sized for about 5-10% greater CFM than the amount of outside air being introduced
into the space. Ducts can be fabric, aluminum, PVC, or galvanized steel. Even though “dry air” is being supplied back
to the pool, do not use duct board or similar materials. If the PoolPak™ unit is installed in an area that is below the
natatorium’s dew point temperature, the ducts may require insulation, pitching and drainage.
Continuous vapor barriers are required between the poolroom and all other interior and exterior spaces because of the
high dewpoint in the poolroom all the time. Care must be taken during design and installation to avoid gaps in the vapor
barriers or building damage may result.
Windows and exterior doors must be selected with adequate thermal insulation (including thermal breaks) to minimize
condensation on their interior surfaces even if the supply air is directed across these components. Doors and windows
must also have as low an air leakage as possible. Although the space will be maintained at a slightly negative pressure,
cold air leaking into the space from poorly sealed openings will negate all of the effects of good thermal insulation.
Section I: Indoor Pool Design

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SECTION II: PRINCIPLES, FUNCTIONS, AND FEATURES
THE MECHANICAL DEHUMIDIFICATION SYSTEM
PRINCIPLES OF OPERATION
The PoolPak™ System is a complete environmental control system designed expressly for indoor swimming pool
enclosures. It takes into account two important factors: the swimming pool occupant (personal comfort) and the
swimming pool environment (the physical structure and surrounding furnishings).
The swimming pool enclosure can be a hostile environment for equipment, decor and building structures. A PoolPak™
System’s major function is to dehumidify the pool enclosure air through a vapor compression cycle. During this cycle
the PoolPak™ System recycles the sensible and latent heat and places it back into the pool water and air as needed. This
recycling process saves money and keeps your pool environment efcient and safe.
Solid state microprocessor technology, working in conjunction with sensors, continually monitors water and air
conditions provide superior occupant comfort. Unlike typical outside air ventilation systems, a PoolPak™ System
recycles energy and blankets the walls and windows with warm, dry air.
PoolPak™ dehumidication systems reduce the energy input required to maintain pool water and air temperatures. By
dehumidifying the air and recycling the latent energy back into the pool air and water, the unit will reduce operating
costs when compared to conventional heating and ventilating systems. Pool water and enclosure heating are still required
but with greatly reduced requirements.
A PoolPak™ unit, when matched correctly to the evaporation rate of the pool water and overall dehumidication
requirements, will efciently maintain the pool air at relative humidity levels between 50% and 60%. It should be noted
that a lower evaporation rate occurs when the pool enclosure’s air temperature is maintained above the pool water
temperature. Evaporation losses, and the energy required to maintain desired room conditions, will dramatically increase
if the air temperature is allowed to fall below the pool water temperature. It is recommended that the continuous dry bulb
temperature entering the evaporator of the PoolPak™ unit not fall below 75°F.
PoolPak™ International recommends that backup heating equipment for both pool water and pool enclosure air is
capable of carrying the full system heating requirements. This makes for a well-designed system that will provide the
least amount of pool down time if unforeseen system problems occur. Building conductive loads and other losses must
be taken into consideration.
AUTOMATIC CONTROL OF AIR TEMPERATURE AND HUMIDITY
An integral part of any PoolPak™ System is a proven microprocessor control system which automatically senses and
maintains comfort conditions. Sensors detect changes in humidity and air temperature in the indoor pool environment
and quickly regulate supply air conditions to meet set point comfort levels, even during periods of unusually heavy pool
use.
To prevent condensation on walls and windows, The PoolPak™ System automatically adjusts humidity in response to
changes in wall or window surface temperatures. As the seasons and weather conditions change, the PoolPak™ System
changes its own mode of operation. Throughout the year, PoolPak™ thinks “efciency” and automatically selects the
least expensive energy source for the poolroom conditions.
PoolPak™ models include a factory mounted and wired space temperature and humidity sensor at the return air opening
of the unit. Refer to the installation section for mounting location. Caution should be exercised. When the outside air is to
be introduced into the space for ventilation, adequate exhaust capacity via an integral (or a separate external fan) must be
specied to ensure the poolroom remains slightly negative. An inadequately sized exhaust system may result in damage
to the structure and pool odors may be forced into other areas of the building.

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ROOM DEW POINT CONTROL
PoolPak™ units with the ECC-PCP controller operate using an advanced type of control called dew point temperature
control. This method of control is more accurate than conventional relative humidity control. The main purpose of a
dehumidication system is to maintain the amount of moisture in the pool area below a level that would cause damage
to the building. Relative humidity is a measurement of the percentage of moisture which is in the air at a given dry
bulb temperature in proportion to the maximum amount of moisture that could be contained at this particular dry bulb
temperature. Warmer air can hold more moisture than colder air and, therefore, changes in dry bulb temperature will
change the relative humidity reading without any change in the actual amount of moisture in the air. The amount of
moisture in the air is expressed as “grains of moisture per pound of dry air” and is directly related to the dew point
temperature.
The ECC-PCP uses dew point control to operate the PoolPak™ unit and maintain the moisture level below the setpoint.
The space dry bulb temperature and relative humidity determine the dew point temperature. By varying the space
temperature and space relative humidity set points, the dew point set point is changed. When the space dew point
temperature rises more than 1/2 degree Fahrenheit above the space dew point temperature set point, the ECC-PCP
controller energizes the compressor for dehumidication. As the dew point temperature drops more than 1/2 degree
Fahrenheit below the dew point temperature set point the controller de-energizes the compressor.
POOLCOMPAK OPERATION
The PoolComPak™ fan draws in warm, moist air from the pool enclosure. This air passes through the evaporator
(dehumidication) coil and gives up heat energy to the refrigerant which is in a cool, liquid state. This exchange of
energy causes the air temperature to fall below its dew point, resulting in moisture condensation on the evaporator coil.
The moisture formed falls into the unit’s condensate drain pan. After passing through the evaporator coil, the refrigerant
becomes a cool gas.
The refrigerant enters the unit’s compressor, where it is compressed into a hot gas. While in the compressor, the
refrigerant absorbs the energy used to operate the compressor. This hot gas refrigerant then travels either through an air
reheat coil, the pool water condenser or to an optional auxiliary air conditioning condenser, which may be either air or
water cooled. If air heating is called for, the air reheat coil is used. The hot refrigerant exchanges energy with the cooler,
dehumidied air coming from the evaporator coil. This causes the temperature of the air to rise for heating.
Figure 2-1. PoolComPak™ AW and HCD Typical Refrigerant System Schematic
PCP_EG_Schematic3D_20121204.tif
Section II: Principles, Functions, and Features

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If pool water heating is required (AWH models only), the hot gas ows into a pool water condenser, where it adds energy
to the incoming pool water. This heats the pool water while the refrigerant is condensed into a warm liquid. If space
cooling is called for, the refrigerant ows to the auxiliary air conditioning condenser bypassing the air reheat coil and
pool water condenser and allowing cool air from the evaporator coil to provide space
ECC-PCP CONTROL SYSTEM
OVERVIEW
The ECC-PCP controller is a micro-processor based system that maintains pool enclosure humidity and air and water
temperatures at optimum levels automatically. It is also possible to monitor this critical data via the Internet using the
optional Remote Access Package (RAP). This also allows the controller to be accessed from the factory via the internet
or a telephone line. (AWH and HCDH only)
The ECC-PCP is designed to work with the PoolComPak™ dehumidication system to provide an environment that is
both comfortable and cost effective. It controls unwanted humidity in the pool enclosure and helps to prevent unsightly
condensation from forming on surfaces.
The ECC-PCP provides accurate control and allows the user to monitor system parameters and change setpoints easily.
For this purpose, a remote interface unit with a text display and keypad is provided. The remote panel should be mounted
outside the pool space, in an ofce or in the equipment room. (The ECC-PCP remote interface unit contains no sensors.)
All setpoints are saved in the memory of the ECC-PCP and are not erased in the event of a power failure. Critical
operating data can be easily accessed by a service technician for the purpose of system operation and evaluation.
HUMIDITY CONTROL
As the dewpoint temperature within the pool enclosure rises above the desired setpoint, the ECC-PCP activates the
compressor within the PoolComPak™ to begin the dehumidication process. If the space temperature is below the
desired setpoint, the heat recovered during dehumidication is directed to the air reheat coil for space heating. If the
pool water temperature is also below the setpoint, some of the recovered heat is directed to the pool water condenser
(model AW only) for pool water heating. If neither air heating nor pool water heating is required, the recovered heat
can be directed to an auxiliary air conditioning condenser if the system is so equipped. If the system does not include an
auxiliary air conditioning condenser, the ECC-PCP will direct the recovered heat to the air reheat coil until the need for
dehumidication is satised.
COLD SURFACE TEMPERATURE HUMIDITY RESET
The ECC-PCP control system includes a sensor that measures the temperature of the coldest surface in the pool
enclosure, usually an exterior window or door frame. When the temperature of this surface approaches the dewpoint
temperature of the space, the controller lowers the humidity setpoint to activate dehumidication. This function helps to
prevent condensation on the cold surface.
SPACE HEATING
When the compressor is running, the ECC-PCP directs the recovered heat to the air reheat coil. Space heating will
continue until the space temperature reaches the setpoint. The ECC-PCP will activate the auxiliary space heating system
if the PoolComPak™ unit is unable to satisfy the heating need with heat recovered during dehumidication. The ECC-
PCP will activate the auxiliary pool water heating system if the water temperature cannot be satised with recovered
heat. An auxiliary pool water heater must be supplied as part of the pool water pump and lter system.
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Section II: Principles, Functions, and Features
NETWORKING MULTIPLE UNITS
ECC-PCP networking allows up to four PoolComPak™ units to be connected together. The units will work with each
other to control water temperature, air temperature, and relative humidity. Networked PoolComPak™ units have all the
features of standard PoolComPak™ plus the ability to control water temperature in multiple pools. They also allow
system dehumidication capacity to be staged. All units on the network are accessible from a single remote interface unit
for convenience.
SPACE COOLING (OPTIONAL)
If space cooling is required and the unit is equipped with an auxiliary air conditioning condenser (air-cooled or water-
cooled), the ECC-PCP will activate the space cooling mode of operation. In this mode, the heat removed from the space
air will be directed to the auxiliary air conditioning condenser. The air cooling mode of operation is independent of the
need for dehumidication.
When the PoolComPak™ unit is equipped with a eld supplied economizer, the ECC-PCP will automatically select the
most economical method for space cooling. An economizer utilizes outside air rather than the refrigeration system to
achieve space cooling. A sensor connected to the ECC-PCP monitors the outside air temperature. When appropriate, the
controller will disable the compressor and bring in cool outside air for economical operation. A separate exhaust system
must be installed to ensure negative room pressure during the economizer mode.
WATER HEATING (MODELS AWV AND AWH ONLY)
If the pool water temperature is also below the set point, some of the recovered heat is directed to the pool water
condenser for pool water heating. Heating can only take place during the dehumidication when heat is captured in the
refrigeration circuit. This is only available on the Model AW, which is equipped with a pool water condenser.
FEATURES AND OPTIONS
STANDARD ITEMS FACTORY MOUNTED
• Evaporator (dehumidication) coil
• Air reheat coil (hot gas reheat coil)
• Bottom, top (for indoor installations) or horizontal supply air conguration
• Filters and lter rack
• Air temperature and relative humidity sensor
• Compressor suction and Discharge pressure transducers
• Compressor suction temperature
STANDARD ITEMS FACTORY SUPPLIED FOR FIELD INSTALLATION
• ECC-PCP control interface device
• Cold surface temperature sensor
• Outside air temperature sensor (with economizer control kit option only)
• Pool water temperature sensor (AW models only)
SYSTEM OPTIONS
• Remote air-cooled condenser for space air conditioning
• Capability of introducing up to 30% outside air
• Economizer control
• Network multiple units
• Remote monitoring via Internet (AWH and HCDH only)
• Weatherproong for outdoor installation (AWH and HCDH only)

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• A factory-mounted water-cooled condenser with a refrigerant head-pressure controlled water regulating valve for
space air conditioning. Chilled water and closed loop cooling tower water may be used for the water-cooled condenser
loop. Never use ground water for the water-cooled condenser. Consult the factory for cooling tower applications.
ROOFPAK SYSTEM
The RoofPak product line is comprised of the most popular PoolComPak™ conguration and repacked as a self-
contained, all-in one dehumidication system. This offering merges a highly reliable PoolComPak™ AWH or HCDH
base system with an integral air-cooled condenser and either an integral gas furnace or an electric heater. The RoofPak
Series is only available in horizontal conguations which can be utilized over a wide range of popular applications. See
the RoofPak section of this manual for more information.
POOLCOMPAK™ DEHUMIDIFICATION SYSTEMS SELECTION
Overview
The PoolComPak™ is a compact unitary pool dehumidication system designed for commercial and residential
applications. It is available in the AW Series with a pool water condenser for water heating or in the HCD Series without
the pool water condenser.
Available Congurations
Indoor Installation: The PoolComPak™ ts easily into a standard utility room (vertical and horizontal congurations)
Outdoor Installation: The horizontal conguration only can be pad, roof or curb mounted depending on the application.
For detailed information for your specic model, please refer to General Arrangement Drawings.
The PoolComPak™ can be congured with an internal hot water coil or duct-mounted electric heater, and adapted for
economizer operation. The horizontal model can have either a top, bottom or end supply duct connection.
Typical AW Series Applications
• Hot Tubs, Spas, and Whirlpools
• Residential Pools
• Hotel and Motel Pools
• School Natatoriums
• YMCA and Club Pools
Typical Non-Pool HCD Series Applications
• Commercial and industrial applications
• Libraries
• Manufacturing
• Agricultural
• Museums
• Archival
• Electronic
• Warehousing/storage
Unit Selection software program
PoolPak™ International LLC maintains a computerized software selection program. Information required for the
program can be found in the PoolComPak Selection Input Data form found in the online PoolPak™ Engineering
Library. Please contact your exclusive PoolPak™ Sales representative for a selection.
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Section II: Principles, Functions, and Features
ROOFPAK SERIES (HCDH/AWH)
PoolPak™ has taken their most popular PoolComPak™ conguration and repacked it as a self-contained, all-in-
one dehumidication system. This product comprises the RoofPak Series. This offering merges a highly reliable
PoolComPak™ AWH or HCDH base system with an integral air-cooled condenser and either an integral gas furnace or
an electric heater. The RoofPak Series is only available in horizontal conguations which can be utilized over a wide
range of popular applications. The ten and twelve ton models are ideally suited for applications having a surface area
between 1,200 sq. ft. and 2,500 sq. ft.
DESIGN FEATURES
The RookPak Series is designed with features that provide cost savings and greater reliability over traditional systems.
Key features are:
• Single, self-contained unit can be installed with one crane lift
• Enclosed refrigerant system reduces refrigerant charge
• Factory assembly ensures wiring and brazing are accomplished under ideal situations
• Single power connection to minimize eld wiring. (Separate power connection required for integral electric heat.)
Durable Construction
• Heavy duty construction designed for outside installation to withstand the elements
• Double-wall construction enhances product longevity
• Designed for quiet operation
Rooftop Installation
• Requires only one mounting curb
• Bottom return air
• Bottom supply air
• Side outside air
Microprocessor Controller
• Utilizes the PoolPak™ proven ECC-PCP, microprocessor based contol technology
• Incorporates Remote Access Package (RAP) to allow system access via the ethernet/internet
• RAP is easily adaptable to BAS systems including BACnet (MS/TP & IP), LonWorks, and Modbus
Heating Packages
• 200 MBH or 240 MBH indirect gas furnace for consistent temperature control
• 20kW or 30kW electric heater (requires separate power connection)
• Hot water coil using PoolPak™ standard Hycor Blue coil or optional Electro-Guard™ coils
Self-Contained Air-Cooled Condensing Section
• Built-in Air Cooled Condenser (ACC) reduces cost and eliminates eld piping
• Utilizes efcient dual rotary blade fans
• Efcient to 105°F ambient outside air temperature
• Choice of coil coatings for specic applications
Evaporator Coil Options
• Hycor Blue (standard)
• Electro-Guard™ Plus
• All copper

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Totally Enclosed, Fan Cooled (TEFC) Motors
• Protects fan motors from corrosive air stream
• Extends motor life/prevents premature failure
• Reduces system maintenance
Unique Outside Air System
• Houses adjustable louvers and lter
• Convenient external lter access
• Swing-out door-mount design for easy service access to fan motor and belts
Housed Blower
• Heavy pillow-block bearings provide durability
• Rugged cast-steel housing provides longevity
• Provides greater reliability
Cupronickel Water Heat Exchanger
• Supplies 100% of available recycled energy to the pool water
• Reaches water temperature set-point conditions faster
• Efciently maintains the water temperature set-point
• Redirects heat only after space temperature is satised
Section II: Principles, Functions, and Features