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ComPak

Series - Installation, Operation and Maintenance |

ComPak

Series IOM

SECTION IV: INSTALLATION

PCP Installation

Introduction

Installation requires the unit to be placed on a roof mounted curb, the mechanical room floor, an appropriate

location in the pool room, or outside on an equipment housekeeping pad. Isolation pads should be placed under

the unit to minimize transmission of noise due to unit operation. Then pool water is piped to the unit. Electrical

power from a properly sized fused disconnect is connected to the unit. The supply and return air ducts are

connected to their respective locations on the unit. The condensate is piped back to the pool or to the sewer.

If an optional remote air-cooled condenser is used, place the condenser in a proper outdoor location.

Refrigerant piping is then run from the air cooled condenser to the ComPak® unit. Refrigerant lines must be

leak checked and evacuated through installer provided Schrader valves. Control and power wiring are run to

complete the installation. If a field-furnished auxiliary space heating coil is installed, the control for this heater

must be field 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 outside. When ventilating the natatorium in this way, an exhaust fan must be

furnished in the natatorium to exhaust to the outside an air volume slightly greater than the air volume introduced

into the natatorium from the outside. This will maintain a negative pressure in the space, preventing odor and

moisture migration. Outside air filters are provided for Horizontal ComPak® units. For Vertical ComPak® units,

outside air must be filtered before entering the unit.

UNIT/FACILITY INTERFACE

A typical ComPak® system layout and its connection to the natatorium and pool water piping systems is shown

in the figure below.

Figure 4-1. Typical ComPak® AWH Series System Layout

Cold Surface

Temperature Sensor

POOL

Recommended Water

PressureTaps

Return Air

CPCS Remote

Interface Unit (should not

be mounted inside

pool enclosure)

Fused

Disconnect (Able to be seen

from the unit)

Remote

Air-Cooled

Condenser

(optional)

ComPak

Horizontal

Unit

Pool Heater

Pump (optional)

Pool Water Circulation Pump

for ComPak (Optional - By Others)

Flo

Pool Water

Temp. Sensor

Balancing Valve

Pool Filter

Pool Pump

Isolation

Valves

Air

Vent

Supply Air Duct

Supply Air

Exterior

Window

Содержание ComPak AW 0550

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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