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