PoolPak R-410A SWHP Series User manual

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POOLPAK R-410A
SWHP SERIES
(MODELS SR, S, SE, SEP)
Engineering Guide
Packaged Natatorium Environment Control System
PoolPakTM SWHP Series
Natatorium Dehumidication Unit
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For unit weights and dimensions, see PoolPak SWHP Weights and Dimensions Guide.

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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 APPLICATION..............................................................................................................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.............................................................................................................................................................................. 5
Return Air.............................................................................................................................................................................. 6
Ductwork Design................................................................................................................................................................... 6
Air Distribution ...................................................................................................................................................................... 6
Air Connections to PoolPak™ .............................................................................................................................................. 7
Other Air-side Considerations............................................................................................................................................... 7
SECTION II: POOLPAK PRINCIPLES, FUNCTIONS, AND FEATURES ..................................................................8
Principles of Operation................................................................................................................................................................. 8
Room Dew Point Control.......................................................................................................................................................... 9
PoolPak™ Operation................................................................................................................................................................ 10
Standard Items Factory Mounted ......................................................................................................................................... 10
Standard Items Factory Supplied for Field Installation ......................................................................................................... 10
System Options .................................................................................................................................................................... 10
ECC Control System.................................................................................................................................................................... 12
Overview .................................................................................................................................................................................. 12
Humidity Control....................................................................................................................................................................... 12
Cold Surface Temperature Humidity Reset.............................................................................................................................. 13
Space Heating.......................................................................................................................................................................... 13
Networking Multiple Units ........................................................................................................................................................ 13
Smart Economizer (SR) ........................................................................................................................................................... 13
Space Cooling (optional).......................................................................................................................................................... 13
Air Conditioning with Air-Cooled Condenser ........................................................................................................................13
Air Conditioning with Water-Cooled Condenser .................................................................................................................. 14
Air Conditioning with Chilled Water Coil .............................................................................................................................. 14
Pool Water Heating .................................................................................................................................................................. 14
Smart Pump Control................................................................................................................................................................. 14
Occupied/Unoccupied Control Mode ....................................................................................................................................... 14
Purge Mode (SR and SEP) ...................................................................................................................................................... 14
CO2 Based Demand Ventilation .............................................................................................................................................. 14
Event Mode (SR) ..................................................................................................................................................................... 14
Selection ...................................................................................................................................................................................... 16
Overview .................................................................................................................................................................................. 16
Available Congurations....................................................................................................................................................... 16
Unit Selection Software Program ............................................................................................................................................. 16

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SECTION III: SIZING AND PERFORMANCE ............................................................................................................17
PoolPak SWHP Unit Dimensions and Weight ............................................................................................................................. 17
PoolPak SWHP Unit Capacity ..................................................................................................................................................... 17
Pool Water Condenser Pressure Drop and Heat Capacity.......................................................................................................... 18
PoolPak Auxiliary Gas Furnace Capacity .................................................................................................................................... 19
PoolPak Auxiliary Electric Heat Capacity..................................................................................................................................... 19
PoolPak Air-Cooled Condenser (ACC) Dimensions, Weight and Electrical................................................................................. 20
Water-Cooled Condenser (WCC) ................................................................................................................................................ 26
SECTION IV: INSTALLATION ....................................................................................................................................29
Overview...................................................................................................................................................................................... 29
Handling ................................................................................................................................................................................... 29
Rigging ..................................................................................................................................................................................... 29
Clearance................................................................................................................................................................................. 29
Foundation ............................................................................................................................................................................... 30
Inspection................................................................................................................................................................................. 30
Unit Hookup.............................................................................................................................................................................. 30
Gas Furnace Auxiliary Heat (Optional) ................................................................................................................................. 30
Power Supply........................................................................................................................................................................ 30
Single Point Power Supply ................................................................................................................................................... 31
Dual Point Power Supply...................................................................................................................................................... 31
Control Wiring....................................................................................................................................................................... 31
Condensate Piping ............................................................................................................................................................... 31
Curb Mounting ...................................................................................................................................................................... 31
ECCIII Controls Field Wiring........................................................................................................................................................ 32
Overview .................................................................................................................................................................................. 32
Remote Interface Unit (1)......................................................................................................................................................... 32
Outside Air Temperature and Relative Humidity Sensor (2)..................................................................................................... 33
Cold Surface Temperature Sensor (3)...................................................................................................................................... 33
Smoke Purge Input (SR only) (4) ............................................................................................................................................. 34
Fire Trip Input (5)...................................................................................................................................................................... 34
Occupied Mode Input (6).......................................................................................................................................................... 34
Purge Mode Input (SR and SEP) (7)........................................................................................................................................ 34
Remote Exhaust Fan Interlock (S only) (8) .............................................................................................................................. 34
Alarm Output (9)....................................................................................................................................................................... 34
Auxiliary Pool Water Heating System (10) ............................................................................................................................... 34
Auxiliary Air Heating System (11) ............................................................................................................................................. 35
System 1 Remote Air-Cooled Condenser Interlock and Control (12)....................................................................................... 35
System 2 Remote Air-Cooled Condenser Interlock and Control (13)....................................................................................... 35
Auxiliary Air Heat Control Valve (14) ........................................................................................................................................ 35
Building Automation System Connection (15) .......................................................................................................................... 35
Multi-unit Network Connection (Multi-unit installations only) (16)............................................................................................. 35
System 1 Remote Water-Cooled Condenser Interlock (If equipped) (17)................................................................................ 36
System 2 Remote Water-Cooled Condenser Interlock (If equipped) (18)................................................................................ 36
Pool Water Temperature Sensor (19)....................................................................................................................................... 36
Smart Pump Control Output (20).............................................................................................................................................. 36
Event Mode (21)....................................................................................................................................................................... 36
Summer Vent Mode (22) .......................................................................................................................................................... 36
Supply Temperature Sensor (not shown)................................................................................................................................. 36
SWHP Field Wiring Diagram.................................................................................................................................................... 37
Pool Water Piping And Installation............................................................................................................................................... 38
PoolPaK Pool Water Circulation Loop...................................................................................................................................... 38
Auxiliary Pool Water Heater (eld supplied)............................................................................................................................. 38
Main Pool Water Pump and PoolPak Pool Water Loop Pump Interlocks................................................................................. 38
Pool Water Isolation Valves...................................................................................................................................................... 38
Pool Water Flow Switch ........................................................................................................................................................... 39
Pool Water Piping Composition................................................................................................................................................ 39
Freeze Protection..................................................................................................................................................................... 39
Condensate Drains And Piping .................................................................................................................................................... 40

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Air-Cooled Condenser Installation ............................................................................................................................................... 41
Space and Location Requirements .......................................................................................................................................... 41
Walls or Obstructions............................................................................................................................................................ 41
Multiple Units ........................................................................................................................................................................ 41
Units in Pits........................................................................................................................................................................... 42
Decorative Fences................................................................................................................................................................ 42
Field Installed Piping ................................................................................................................................................................ 43
Piping Guidelines.................................................................................................................................................................. 43
SECTION V: OPERATION ..........................................................................................................................................47
Remote Interface Unit (RIU) ........................................................................................................................................................ 47
Service Display Connection ..................................................................................................................................................... 47
Multiple Unit Interfacing............................................................................................................................................................ 47
Building Automation System (BAS) Connection....................................................................................................................... 48
PoolPak Remote Access Package (RAP) ................................................................................................................................ 48
Send Emails – Alerts for Alarms............................................................................................................................................... 48
ECC III Network Operation .......................................................................................................................................................... 48
CM1 Conguration ................................................................................................................................................................... 49
RIU Conguration..................................................................................................................................................................... 49
Network Conguration.............................................................................................................................................................. 50
Network Ctl - No (Yes or No) ............................................................................................................................................... 50
Water Temp Ctl - Local (Local or Net) .................................................................................................................................. 50
Changing Network Set Points .................................................................................................................................................. 50
ECC III Service Troubleshooting.................................................................................................................................................. 51
Troubleshooting Overview........................................................................................................................................................ 51
Alarm Reset.............................................................................................................................................................................. 51
Supply Fan Not Running ...................................................................................................................................................... 51
Return Fan Not Running (SR only)...................................................................................................................................... 51
Fire Trip Active ..................................................................................................................................................................... 52
Smoke Purge Active ............................................................................................................................................................ 52
Return Air Temperature Out of Range ................................................................................................................................. 52
Supply and Return Fans Not Running ................................................................................................................................. 52
Freeze Danger, Low Supply Air Temperature ...................................................................................................................... 52
Low Compressor Oil Pressure (Recip Compressors only) ................................................................................................... 52
High Compressor Motor Temperature .................................................................................................................................. 52
High Refrigerant Pressure .................................................................................................................................................... 52
Low Refrigerant Pressure .................................................................................................................................................... 52
Compressor Current Transducer Failed ............................................................................................................................... 52
10 Fault Compressor Lockout .............................................................................................................................................. 53
Sensor Failure (All Sensors) ................................................................................................................................................ 53
Expansion Board Comm Failure .......................................................................................................................................... 53
Fault History Log ..................................................................................................................................................................... 53
Manual Control ........................................................................................................................................................................ 54
Digital Output ....................................................................................................................................................................... 54
Analog Output ...................................................................................................................................................................... 55
System Status Information ...................................................................................................................................................... 56
Data Log Retrieval.................................................................................................................................................................... 59
Maintenance ................................................................................................................................................................................ 60
Overview .................................................................................................................................................................................. 60
Daily Maintenance.................................................................................................................................................................... 60
Monthly Maintenance ............................................................................................................................................................... 60
Annual Maintenance................................................................................................................................................................. 61
SECTION VI: WIRING.................................................................................................................................................63
Single Point Power Connection ................................................................................................................................................... 63
Dual Point Power Connection...................................................................................................................................................... 63
Remote Connections ................................................................................................................................................................... 64
Multiple Unit Interface .................................................................................................................................................................. 65

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LIST OF FIGURES
Figure 2-1. Dew Point Control Psychrometric.............................................................................................................................. 9
Figure 2-2. SWHP SR System Schematic................................................................................................................................... 11
Figure 2-3. SWHP SEP System Schematic................................................................................................................................. 11
Figure 2-4. Typical PoolPak™ Rooftop Installation...................................................................................................................... 15
Figure 3-1. Air Cooled Condenser Dimensions - End View ......................................................................................................... 25
Figure 3-2. Air Cooled Condenser Dimensions - Side View ....................................................................................................... 25
Figure 3-3. Remote Cooling Tower Dimensions .......................................................................................................................... 26
Figure 3-4. PoolPak™ Optional Water-Cooled Condenser Cabinet - Attached........................................................................... 27
Figure 4-1. Field Wiring Diagram................................................................................................................................................. 37
Figure 4-2. Pool Water Piping Schematic .................................................................................................................................... 39
Figure 4-3. Negative Pressure Condensate Piping Schematic.................................................................................................... 40
Figure 4-4. Remote ACC Installation Around Walls or Obstructions............................................................................................ 41
Figure 4-5. Remote ACC Installation When Installing Multiple Units ........................................................................................... 41
Figure 4-6. Remote ACC Installation When Installing Units in Pits.............................................................................................. 42
Figure 4-7. Remote ACC Installation When Installing Units Near Decorative Fences................................................................. 42
Figure 4-8. Remote ACC Above Unit ........................................................................................................................................... 44
Figure 5-1. Remote Interface Unit Graphic.................................................................................................................................. 47
Figure 5-2. Data Retrieval Using USB Key.................................................................................................................................. 59
Figure 6-1. Single Point Power Connection................................................................................................................................. 63
Figure 6-2. Dual Point Power Connection ................................................................................................................................... 63
Figure 6-3. Remote Connections................................................................................................................................................. 64
Figure 6-4. Multiple Unit Interface................................................................................................................................................ 65
LIST OF TABLES
Table 1-1. Typical Pool Water and Air Temperature Set-Points ................................................................................................... 2
Table 1-2. Recommended Pool Water Chemistry........................................................................................................................ 3
Table 3-1. PoolPak™ SWHP Unit Capacity................................................................................................................................. 17
Table 3-2. Pool Water Condenser Pressure Drop and Heat Capacity ......................................................................................... 18
Table 3-3. PoolPak™ Auxiliary Gas Furnace Capacity ................................................................................................................ 19
Table 3-4. PoolPak™ Auxiliary Electric Heat Capacity ................................................................................................................ 19
Table 3-5. ACC - Model SWHP 0060 ........................................................................................................................................... 20
Table 3-6. ACC - Model SWHP 0080 ........................................................................................................................................... 20
Table 3-7. ACC - Model SWHP 0100 ........................................................................................................................................... 21
Table 3-8. ACC - Model SWHP 0120 ........................................................................................................................................... 21
Table 3-9. ACC - Model SWHP 0140 ........................................................................................................................................... 22
Table 3-10. ACC - Model SWHP 0190 ......................................................................................................................................... 22
Table 3-11. ACC - Model SWHP 0220 ......................................................................................................................................... 23
Table 3-12. ACC - Model SWHP 0260 ......................................................................................................................................... 23
Table 3-13. ACC - Model SWHP 0300 ......................................................................................................................................... 24
Table 3-14. ACC - Model SWHP 0340 ......................................................................................................................................... 24
Table 3-15. Remote Water Cooled Condenser Dimensions ........................................................................................................ 26
Table 3-16. WCC Piping Connections.......................................................................................................................................... 26
Table 3-17. Water Cooled Condenser Performance .................................................................................................................... 28
Table 4-1. Pipe Sizes for Remote Refrigerant Condensers ......................................................................................................... 44
Table 4-2. Remote ACC Refrigerant (R-410A) Charge ................................................................................................................ 45
Table 4-3. Refrigerant (R-410A) Charge for Different Line Sizes................................................................................................. 45
Table 5-1. Recommended Pool Water Chemistry........................................................................................................................ 60

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SECTION I: INDOOR POOL APPLICATION
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. 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. To control the buildup
of chloramines and gases in an enclosed poolroom, the space must have an adequate supply of outside air or ventilation
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A strong “chlorine” odor is an indicator of poor pool water chemistry and is generally offensive to the occupants. Higher
levels of chloramines can cause skin/eye irritation and respiratory problems commonly known as “lifeguard lung”.
Most poolrooms are designed with a minimum ventilation rate to dilute the airborne pollutants generated from the
chemical interactions in the pool water. Typically these rates are based on ASHRAE standard 62.1 and dictated by local
codes at about 0.5 CFM/square foot of pool and deck area, but depending on the pool water chemistry the ventilation rate
may not always be adequate for good poolroom IAQ.
However, increasing ventilation rates can signicantly add to the cost of operation. Energy conservation strategies such
as heat recovery, airow measurement and CO2 based control help control costs while improving IAQ.
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°F with the air temperature about 2˚F higher to
prevent chilling when exiting the pool and to minimize evaporation from the pool surface. Refer to Table 1 for 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, while warmer temperatures are more
common for seniors or children or less active pools.
The desirable humidity range is generally between 50 and 60%. A humidity level greater than 60% can create a sticky
feeling and difculty breathing. A humidity level lower than 50% will result in evaporative cooling on the bather’s skin,
creating 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 and Air Temperature Set-Points
Water Temp. oFAir Temp. oF Room RH %
Recreational Pools 80-85 Water Temp + 2 55-60
Therapy Pools 86-92 86155-60
Whirlpools 99-104 86155-60
1Normally max 86 oF to minimize overheating of occupants
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/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. See “Indoor Pool Water Chemistry – Controlling Chloramines with Proper Chlorine Management,”
MK2-BROPOOLCHEM, for more information on pool water chemistry.

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Table 1-2. Recommended Pool Water Chemistry
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
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 ventilation 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 ventilation 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 Dehumidication
• Moisture removal is accomplished through mechanical refrigeration
• Signicant heat recovery using “heat pump” technology
• Recovers the most energy from the ventilation 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

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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.