PoolPak ComPak AW 0550 Installation, Operation And Maintenance Manual Download Page 17 | Manualshive

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© 2017 PoolPak LLC. All rights reserved.

ComPak

®

Series - Installation, Operation and Maintenance |

17

ComPak

®

Series IOM

Evaporator Coil Options

•  Hycor® Blue (standard)
•  Electro-Guard® Plus
•  All copper

Electronically Commutated (EC) Fans

•  Integral fan motor and drive for easy fan speed adjustment
•  Direct drive reduces system maintenance
•  Quieter, lower energy use

Unique Outside Air System

•  Houses adjustable louvers and filter
•  Convenient external filter access
•  Swing-out door-mount design for easy service access to fan motor and belts

Cupronickel Water Heat Exchanger

•  Supplies 100% of available recycled energy to the pool water
•  Reaches water temperature set-point conditions faster
•  Efficiently maintains the water temperature set-point
•  Redirects heat only after space temperature is satisfied

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Summary of Contents for ComPak AW 0550

Page 1: ...tion Operation and Maintenance ComPak R 410A AW HCD Series RoofComPak Series HCD High Capacity Dehumidifier AW Air and Water Horizontal H and Vertical V Configurations FORM SVW06 PCPIOM 20170808 SUPER...

Page 2: ...r Temperature and Humidity 11 Room Dew Point Control 12 ComPak Operation 12 CommandPak Control System 13 Overview 13 Humidity Control 13 Cold Surface Temperature Humidity Reset 14 Space Heating 14 Net...

Page 3: ...ak Units 31 Inspection 31 Power Supply 31 Control Wiring 31 Condensate Piping 31 Curb Mounting 32 Integral Gas Furnace Option RoofComPak Only 33 CPCS PCP Controls Field Wiring 34 Overview 34 Remote In...

Page 4: ...Configuration 57 History 61 Utilities 63 Startup 63 Pre Start Checklist 63 Start Up 64 Troubleshooting 65 Data Log Retrieval 67 Network Troubleshooting Guide 68 Troubleshooting Guide 69 Maintenance 7...

Page 5: ...l Unit Elevation and End Views 21 Figure 3 2 AW HCD Vertical Unit Elevation and Plan Views 22 Figure 3 3 Air Cooled Condenser PoolPak Isometric Views 27 Figure 3 4 Air Cooled Condenser Bohn Elevation...

Page 6: ...6 1 Auxiliary Air and Pool Water Heater Connections for Multiple Units 71 Figure 6 2 Auxiliary Air and Pool Water Heater Connections for Two Pool Installations 72 Figure 6 3 Field Wiring Diagram 73 Fi...

Page 7: ...with this warning may result in personal injury or equipment damage PoolPak Service department must be contacted at least 2 weeks prior to equipment startup A PoolPak authorized service technician wi...

Page 8: ...c 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 rough...

Page 9: ...f 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 o...

Page 10: ...e 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 affe...

Page 11: ...ments A PoolPak unit when matched correctly to the evaporation rate of the pool water and overall dehumidification requirements will efficiently maintain the pool air at relative humidity levels betwe...

Page 12: ...rectly related to the dew point temperature The CPCS PCP uses dew point control to operate the PoolPak unit and maintain the moisture level below the setpoint The space dry bulb temperature and relati...

Page 13: ...to provide an environment that is both comfortable and cost effective It controls unwanted humidity in the pool enclosure and helps to prevent unsightly condensation from forming on surfaces The CPCS...

Page 14: ...ill work with each other to control water temperature air temperature and relative humidity Networked ComPak units have all the features of standard ComPak plus the ability to control water temperatur...

Page 15: ...old surface temperature sensor Outside air temperature sensor with economizer control kit option only Pool water temperature sensor AW models only System Options Remote air cooled condenser for space...

Page 16: ...ions Single power connection to minimize field wiring Separate power connection required for integral electric heat Durable Construction Heavy duty construction designed for outside installation to wi...

Page 17: ...rive reduces system maintenance Quieter lower energy use Unique Outside Air System Houses adjustable louvers and filter Convenient external filter access Swing out door mount design for easy service a...

Page 18: ...3500 10 TON AWH HCDH 4000 12 TON Pool Size Sq Ft 1 200 2 000 1 400 2 500 Reheat Capacity MBH 170 200 Moisture Removal Lb Hr 82 F 60 RH 63 70 Pool Water Flow GPM 26 28 Pool Water Condenser PD FT WC 20...

Page 19: ...60 15 7 22 1 47 5 6 10 50 11 7 24 9 45 7 1200 1700 60 20 8 26 9 57 9 10 24 50 15 5 30 5 55 5 1400 2300 60 26 0 38 4 76 6 10 8 50 18 8 43 4 73 6 1800 2500 60 30 9 41 8 89 1 12 12 50 22 9 47 8 86 1 2600...

Page 20: ...REMOVAL LBS HR SENSIBLE COOLING CAPACITY MBH ACC MAX HEAT REJECTION MBH 0550 900 60 10 2 13 2 30 5 50 7 7 15 2 29 5 0800 1600 60 14 5 20 8 46 2 50 10 3 23 9 44 4 1200 1700 60 19 0 25 2 56 4 50 14 5 2...

Page 21: ...nt H Lo W Lr W OA Front or Top No Rain Hood OA Front Rain Hood RA Bottom Ho Hr Lro W H RA Rear OA Top Rain Hood Lrr W Hro Lrt W H MODEL NUMBER 550 800 1200 1400 1800 2600 3500 4000 WIDTH BASIC W 33 9...

Page 22: ...L W Lr H OA Side RA Rear L Wo Lr H OA Top RA Rear L W Lr Ho MODEL NUMBER 550 800 1200 1400 1800 2600 3500 4000 WIDTH BASIC W 32 1 32 1 32 1 38 8 38 8 49 6 68 2 68 2 SIDE OA Wo 39 0 39 0 39 0 45 7 45...

Page 23: ...OA TR 800 2500 Left OA LT V3500 4000 Top A 14 x 10 OA TR 0 800 Left OA LT Top C 14 x 30 OA TR 800 2800 Left OA LT COMPAK HORIZONTAL AWH HCDH H550 800 1200 Top A 12 x 12 OA TC 0 450 Front OA FC Top B 1...

Page 24: ...RATE RANGE GPM HEATING CAPACITY RANGE MBH MIN MAX MIN MAX 0550 5 15 33 54 0800 5 15 43 66 1200 5 15 48 75 1400 10 25 71 105 1800 10 25 80 111 2600 15 35 104 161 3500 20 40 147 203 4000 20 40 158 209 H...

Page 25: ...Table 4 3 in the Installation section NOTE Factory Refrigerant Charge Table 3 7 Factory Refrigerant R410A Charge UNIT FACTORY CHARGE1 R410A AIR COOLED CONDENSER ACC WATER COOLED CONDENSER WCC MODEL LB...

Page 26: ...8 1 2 120 3 1 5 3 8 1 9 ACC0051 110 3 4 1 2 120 ACC0081 115 7 8 5 8 210 1200 ACC0051 95 100 105 39 3 3 4 1 2 120 3 1 5 3 8 1 9 ACC0081 110 7 8 5 8 210 ACC0121 115 39 3 1 1 8 3 4 470 6 3 7 5 3 8 1400...

Page 27: ...ondenser PoolPak Isometric Views Figure 3 4 Air Cooled Condenser Bohn Elevation Views SINGLE FAN DUAL FAN ALL DIMENSIONS ARE IN INCHES 45 4 42 3 43 130 120 38 49 1 24 5 16 21 5 9 8 OPTIONAL EXTERNAL E...

Page 28: ...ds on three sides to match heater flanges as shown 2 Fasten heater to duct using sheet metal screws for smaller heaters or bolts for larger ones 3 Seal opening with suitable sealing compound 4 If need...

Page 29: ...ield wired to the ComPak controls shown in Figure 4 8 Outside air can be ducted into the unit through the optional outside air duct connection The unit can draw up to 30 of its supply air from the out...

Page 30: ...e immediately installed it must be protected from weather and site hazards For ComPak rigging refer to the generic or job specific product drawing in the Technical Product Library For RoofComPak riggi...

Page 31: ...o determine the minimum wire size for incoming electrical power The ground connection for the unit is located in the unit control panel The power supply to the unit must be adequate for the compressor...

Page 32: ...he ComPak using the gasket supplied with the curb Install counter flashing provided with the curb separately between the curb and the ComPak unit Seal any piping connections where piping is going thro...

Page 33: ...HASE SBW 15 7 18 6 8 4 8 4 SBA 10 6 13 6 13 3 18 6 SBB 12 15 5 14 9 21 SBL CW Rotation 44 8 53 5 72 8 66 7 SBL CCW Rotation 41 7 49 3 59 59 Note Dimensions relate to Figure 4 4 Integral Gas Furnace Op...

Page 34: ...upplied 6 ft cable RJ25 6 conductor must be installed between the ComPak unit and the control panel For distances greater than 6 feet use 6 conductor 22 AWG shielded twisted pair cable along with the...

Page 35: ...CS PCP may be connected directly to the economizer control circuit provided the circuit is 24 VAC maximum and the current does not exceed 1 amp inductive The other components of the system must be pro...

Page 36: ...in wire to ground at the ComPak end only See figure below for an illustration of the outside air temperature sensor Seal the conduit leading to the sensor with silicone caulk to prevent moisture from...

Page 37: ...the circuit is 24 VAC maximum and the current through the contacts does not exceed 1 amp inductive Figure 4 9 shows a typical installation that utilizes a 3 way hot water control valve and a unit or...

Page 38: ...return duct upstream of the exhaust duct connection See Figure 4 6 Economizer Operation for a typical location of the sensor in the economizer system When field mounting is necessary the sensor will b...

Page 39: ...ACE UNIT SUPPLIED BY POOLPAK INSTALLED BY CUSTOMER CPCS CAREL pGD0 CONTROL PANEL POOL WATER TEMPERATURE SENSOR OPTIONAL CONNECTION TO CONTROL PANEL USE 22 AWG SHIELDED TWISTED PAIR CABLE PAIR 1 MULTI...

Page 40: ...taining the flow rate as specified for the installed unit see ComPak AW Performance in Table 3 1 To ensure correct water flow the filter pump usually operates at the same time as the ComPak unit Howev...

Page 41: ...ed to a common drain system and must be trapped for proper operation For AWH and HCDH units a trap and piping must be supplied and installed by the customer The trap depth must be a minimum of 6 inche...

Page 42: ...this essential requirement is not adhered to it will result in higher head pressures which cause poor operation and possible eventual failure of equipment Units must not be located in the vicinity of...

Page 43: ...between the units is 4 feet Figure 4 14 Remote ACC Installation When Installing Multiple Units UNITS IN PITS The top of the unit should be level with the top of the pit and side distances increased to...

Page 44: ...igerant pressure drops Use long radius elbows wherever possible with one exception short radius elbows should be used for any traps in the hot gas riser Braze all copper to copper joints with a phosph...

Page 45: ...ed Condenser section for these units and the proper system refrigerant charge will prevent this problem Discharge lines should be designed to prevent condensed refrigerant and oil from draining back t...

Page 46: ...and oil For the additional oil required multiply 2 of additional refrigerant charge of both ACC and refrigerant line length Use the correct oil type of POE oil depending on the compressor installed F...

Page 47: ...11 5 6 8 1 10 13 1800 3 4 0 25 1 2 0 92 1 13 3 10 5 8 7 5 7 8 0 34 5 8 1 48 2 14 5 11 8 9 11 6 2600 3 4 0 25 5 8 1 48 2 11 5 6 8 1 10 13 1 1 8 0 58 3 4 2 21 4 6 8 12 13 1 17 7 3500 7 8 0 34 5 8 1 48 2...

Page 48: ...est please wait image will appear for approximately 3 to 5 seconds followed by an initial startup screen as shown below Figure 5 2 Initial Startup Screen After approximately 5 minutes the RIU will dis...

Page 49: ...m DEHUMID SURFACE YES or NO Indicates the space requires dehumidification The word SURFACE indicates that the unit is temporarily lowering the dew point set point to minimize condensation at the cold...

Page 50: ...ilable set points are shown in the following examples AIR TEMPERATURE Figure 5 6 Air Temperature Selection on the Set Points Menu Figure 5 7 Air Temperature Set Point Change Screen For air temperature...

Page 51: ...l open introducing large quantities of outside air to the space This is typically used when shocking the pool Compressor operation is disabled during purge but the auxiliary air and water heating syst...

Page 52: ...erature and relative humidity set points Figure 5 11 Detailed Status Screen 2 Detailed Status Screen 2 display run hours Disch Press The measured refrigerant pressure in the discharge line at the comp...

Page 53: ...configured for multi unit networking It displays the following Network Role Indicates if the unit currently being displayed by the RIU is the master or a slave Net Status Indicates CONNECTED if the un...

Page 54: ...en that displays the status of units one through four as present or not Use this screen to verify that all units on the network are connected and communicating with each other The figure below shows t...

Page 55: ...ny of the set points The other screens for Pool Water Temperature Control Staged Dehumidification and Stage 2 Offset are not available when this parameter is set to NO CHANGING SET POINTS Each unit on...

Page 56: ...edly until the status screens are shown The following sub menus are available in the service menu I O Configuration Digital Inputs Digital Outputs Analog Inputs Unit Configuration Installed Options Au...

Page 57: ...menu contains a screen for each digital output Each screen contains the following parameters Current output status This read only parameter is shown as On or Off Requested output status This read only...

Page 58: ...face Temperature Min 20 0 Max 195 0 Outside Air Temperature Min 20 0 Max 195 0 Analog Outputs The following analog output applies for RoofComPak models units with EC fans SupFanSpd Supply Fan Speed th...

Page 59: ...ssor for air heating when there is no dehumidification requirement Do not change this parameter to Yes unless instructed by the factory service department Deadband 1 0 F Range 1 0 2 0 F This parameter...

Page 60: ...or Network This parameter indicates whether the unit should control pool temperature based on the network requirement or its own internal temperature sensor A setting of Local should be used if this...

Page 61: ...is stored and displayed for each fault Hour at which the fault occurred This is the number of hours since the dehumidifier was last powered on FAULT CODE NUMBER A 2 digit fault code for indicating an...

Page 62: ...talled economizer damper system DIGITAL OUTPUT CONTROL Fan Motor Auto On or Off Set to On or Off to force the dehumidifier fan on or off Compressor Auto On or Off Set to On or Off to force the dehumid...

Page 63: ...rdance with local and NEC codes Check for proper power supply and a properly sized and installed fused disconnect switch located within sight of the ComPak unit Ensure that proper pool water flow and...

Page 64: ...Department P O Box 3331 York PA 17402 Or fax to 717 718 4245 Or scan and email to service poolpak com LOW VOLTAGE DO NOT be misled by the term low voltage Voltages as low as 50 volts may cause death...

Page 65: ...button will glow red and the remote interface unit will display the fault condition and a recommended course of action If the fault is a high pressure low pressure or defrost the CPCS PCP will displa...

Page 66: ...that a sensor attached to the CPCS PCP has failed Depending on which sensor has failed some functions of the ComPak unit may be disabled until the sensor is repaired This alarm screen will show the st...

Page 67: ...and press Enter to confirm Select USB pen drive and press ENTER Wait a few seconds after the pendrive has been plugged in for it to be recognized by the controller If the message No USB disk or PC co...

Page 68: ...work 1 Correct the network connection 2 Unit is not powered on 2 Apply power to all units Units working against each other 1 heat 2 cool etc 1 Network Control parameter set to NO on some units 1 Set N...

Page 69: ...ecover evacuate and charge system 5 Reheat solenoid not opening 5 Repair reheat solenoid Fan On Compressor Off Display shows Compress Hi Pressure Trip code 100 or 101 1 A C condenser power off 1 Resto...

Page 70: ...at the scroll does not rub the housing Check for proper belt tension Worn or cracked belts should be replaced Check fan and mounting brackets for tightness Ensure that the ALARM light is not illuminat...

Page 71: ...Pak Series Installation Operation and Maintenance 71 ComPak Series IOM SECTION VI WIRING Auxiliary Air Pool Water Heater Connections for Multiple Unit Installation Figure 6 1 Auxiliary Air and Pool Wa...

Page 72: ...59 7725 72 ComPak Series Installation Operation and Maintenance Auxiliary Air Pool Water Heater Connection for a Two Pool Installation Figure 6 2 Auxiliary Air and Pool Water Heater Connections for Tw...

Page 73: ...NTERFACE UNIT SUPPLIED BY POOLPAK INSTALLED BY CUSTOMER CPCS CAREL pGD0 CONTROL PANEL POOL WATER TEMPERATURE SENSOR OPTIONAL CONNECTION TO CONTROL PANEL USE 22 AWG SHIELDED TWISTED PAIR CABLE PAIR 1 M...

Page 74: ...www poolpak com 800 959 7725 74 ComPak Series Installation Operation and Maintenance Fire Control System Connection Figure 6 4 Fire Control System Connection...

Page 75: ...2017 PoolPak LLC All rights reserved ComPak Series Installation Operation and Maintenance 75 ComPak Series IOM Factory Wiring Diagrams Figure 6 5 ComPak AW HCD Main Schematic Single Phase I n t...

Page 76: ...www poolpak com 800 959 7725 76 ComPak Series Installation Operation and Maintenance Figure 6 6 ComPak AW HCD Main Schematic Three Phase...

Page 77: ...2017 PoolPak LLC All rights reserved ComPak Series Installation Operation and Maintenance 77 ComPak Series IOM Figure 6 7 ComPak AW HCD Point to Point Schematic Single Phase Vertical Unit...

Page 78: ...www poolpak com 800 959 7725 78 ComPak Series Installation Operation and Maintenance Figure 6 8 ComPak AW HCD Point to Point Schematic Three Phase Vertical Unit...

Page 79: ...2017 PoolPak LLC All rights reserved ComPak Series Installation Operation and Maintenance 79 ComPak Series IOM Figure 6 9 ComPak AW HCD Point to Point Schematic Single Phase Horizontal Unit...

Page 80: ...www poolpak com 800 959 7725 80 ComPak Series Installation Operation and Maintenance Figure 6 10 ComPak AW HCD Point to Point Schematic Three Phase Horizontal Unit...

Page 81: ...2017 PoolPak LLC All rights reserved ComPak Series Installation Operation and Maintenance 81 ComPak Series IOM Figure 6 11 RoofComPak Factory Wiring Diagram n a l...

Page 82: ...800 959 7725 82 ComPak Series Installation Operation and Maintenance 3491 Industrial Drive York Pennsylvania 17402 USA 800 959 7725 Fax 717 757 5085 2017 PoolPak LLC All rights reserved DRAFT SVW06 P...

Page 83: ...dance with the MCA MOCP info on ComPak unit data plate ___ 3 If the Remote Interface Unit display keypad is mounted remotely verify that the wiring is correct based on the field wiring diagram If you...

Page 84: ...ntact the factory ___ 3 On the ComPak electrical panel the white 2 pole breaker labeled TR1BR and place the Control Power Breaker CPBR in the ON position The CommandPak CM1 will display Loading the RI...

Page 85: ...change the number to 9995 and press the ENTER button The display will show Main Menu Service Manual Mode Demand Control Press the UP ARROW to select Main Menu Service Manual Mode Digital Outp Ctl and...

Page 86: ...ss the ENTER button Password Required is displayed Use the UP ARROW to change the number to 0005 and press the ENTER button Press the UP ARROW to select Main Menu Service Manual Mode and then press th...

Page 87: ...Demand Control Press the ENTER button Press the ENTER button to move the cursor next to POOL HEAT Press the UP ARROW to change it from NO to YES and press ENTER ___ 4 After 5 minutes press the PRG but...

Page 88: ...lay should show Main Menu Service Manual Mode Demand Control Press the ENTER button Press the ENTER button to move the cursor next to CMPR HEAT Press the UP ARROW to change it from YES to NO and press...

Page 89: ...displayed Use DOWN ARROW to change the number to 9995 and press the ENTER button ___ 3 Go through the options to set them per the job Enable Network Ctl YES or NO Pool Temp Ctl YES or NO Staged Dehum...

Page 90: ...P 20170630 8 GENERAL INSTALLATION NOTES WARNING The factory warranty is VOID if a completed copy of the ComPak Warranty Registration Startup Form is not provided to PoolPak Service within 7 days of th...

Page 91: ...2017 PoolPak LLC All rights reserved ComPak Series Installation Operation and Maintenance 91 ComPak Series IOM THIS PAGE INTENTIONALLY LEFT BLANK...

Page 92: ...ecklist are required or the unit warranty will be voided Follow the instructions as specified WARNING 3491 Industrial Drive York Pennsylvania 17402 USA 800 959 7725 Fax 717 757 5085 2017 PoolPak LLC A...

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