PoolPak MPK series Istruzioni per l'installazione e il funzionamento

Installation, Operation and

Maintenance

MPK Series

FORM #: SVW07-MPKIOM-20170601

SUPERCEDES: SVW07-MPKIOM-20170331

UPDATED: JUNE, 2017

With more than 45 years of experience in indoor pool dehumidification equipment manufacturing, PoolPak®LLC is the most well-known brand in the

industry. Our people and products work daily to improve the quality and comfort of indoor pool environments. PoolPak®dehumidification solutions include

a variety of heating, ventilation, and air conditioning systems, in addition to an industry-leading PoolPak®support network. For more information, please

visit www.PoolPak.com.

3491 Industrial Drive

York, Pennsylvania 17402 USA

800-959-7725 Fax 717-757-5085

TABLE OF CONTENTS

IMPORTANT ................................................................................................................................ 7

Warning ....................................................................................................................................................7

Intended Users............................................................................................................................................7

SECTION I: INDOOR POOL APPLICATION...................................................................................... 8

Introduction ................................................................................................................................................8

Creating an Ideal Environment for Indoor Pool Facilities...................................................................................8

Operating Cost...........................................................................................................................................8

Application ................................................................................................................................................8

Moisture Loads ...........................................................................................................................................8

Effects of Moisture.......................................................................................................................................8

Indoor Air Quality.......................................................................................................................................9

Occupant Comfort ......................................................................................................................................9

Pool Water Chemistry................................................................................................................................10

SECTION II: PRINCIPLES, FUNCTIONS AND FEATURES.................................................................. 11

The Mechanical Dehumidification System..................................................................................................... 11

Principles of Operation .............................................................................................................................. 11

Automatic Control of Air Temperature and Humidity...................................................................................... 11

Room Dew Point Control............................................................................................................................. 12

PoolPak Operation ....................................................................................................................................13

Air-Side Operation ....................................................................................................................................13

CPCS Control Functions .............................................................................................................................15

Overview .................................................................................................................................................15

Air Flow Monitoring and Control.................................................................................................................15

Humidity Control....................................................................................................................................... 16

Cold Surface Temperature Hunidity Reset.....................................................................................................17

Space Heating..........................................................................................................................................17

Smart Economizer (SEP) ............................................................................................................................. 17

Flywheel Air Conditioning (SEP).................................................................................................................. 17

Space Cooling (Optional) .......................................................................................................................... 17

Smart Pump Control (Optional) ................................................................................................................... 18

Networking Multiple Units.......................................................................................................................... 18

Occupied/Unoccupied Control Mode .........................................................................................................18

Air Conditioning with Air-Cooled Condenser ................................................................................................ 18

Air Conditioning with Water-Cooled Condenser ........................................................................................... 18

Air Conditioning with Chilled Water Coil .....................................................................................................18

Pool Water Heating................................................................................................................................... 18

Purge Mode (SEP) .....................................................................................................................................19

Event Mode (SEP)......................................................................................................................................19

Summer Ventilation Mode (SEP) .................................................................................................................. 19

CO2Based Demand Ventilation (Optional)...................................................................................................19

Features and Options ................................................................................................................................20

Standard Factory Mounted Features ............................................................................................................20

Standard Factory Supplied, Field Installed Features .......................................................................................20

Optional Factory Mounted Features ............................................................................................................20

PoolPak®MPK Series IOM

Optional Field Installed Features ................................................................................................................. 21

Selection.................................................................................................................................................. 21

SECTION III: SIZING AND PERFORMANCE................................................................................... 22

PoolPak Unit Dimensions and Weights .........................................................................................................22

MPK Performance Summary .......................................................................................................................23

MPK Factory Charge .................................................................................................................................23

PoolPak Remote ACC Specifications ............................................................................................................24

Non-PoolPak Provided Air-Cooled Consenser Selection Procedure ..................................................................24

Remote Cooling Tower Condenser Sizing and Performance............................................................................25

Water Cooled Condenser Sizing and Performance .......................................................................................26

PoolPak Pool Water Condenser...................................................................................................................27

PoolPak Auxiliary Gas Furnace Option ........................................................................................................28

PoolPak Auxiliary Electric Heat Option ........................................................................................................28

SECTION IV: INSTALLATION........................................................................................................ 29

MPK Installation ........................................................................................................................................29

Introduction ..............................................................................................................................................29

Handling..................................................................................................................................................30

Rigging ....................................................................................................................................................30

Clearance ................................................................................................................................................30

Dust Installation.........................................................................................................................................30

Mounting .................................................................................................................................................30

Foundation ...............................................................................................................................................30

Inspection................................................................................................................................................. 31

Unit Hookup ............................................................................................................................................. 31

Gas Furnace Auxiliary Heat Option ............................................................................................................ 31

Power Supply............................................................................................................................................ 31

Control Wiring..........................................................................................................................................32

Condensate Piping ....................................................................................................................................32

Curb Mounting .........................................................................................................................................33

CPCS Controls Field Wiring .......................................................................................................................34

OVERVIEW ..............................................................................................................................................34

REMOTE INTERFACE UNIT (1) ....................................................................................................................34

Multi-Unit Network Connection (2) ..............................................................................................................35

Building Automation System Connection (3)..................................................................................................35

Cold Surface Temperature Sensor (4)...........................................................................................................36

Supply Air Temperature Sensor (5) ..............................................................................................................36

Remote Space Pressure Sensor (Optional) (6)................................................................................................36

ACC OR WCC Proof Interlock (7) ...............................................................................................................36

Freezestat (8) (Special Applications Only) ....................................................................................................36

Remote Exhaust Fan Status (9).....................................................................................................................37

Summer Ventilation Mode (SE/MSEP Only) (10)............................................................................................37

Event Mode Interlock (11) ...........................................................................................................................37

Purge Mode Input (SEP ONLY)(12)...............................................................................................................37

Occupied Mode Input (13) .........................................................................................................................37

Fire Trip Input (14) .....................................................................................................................................37

Smoke Purge Input (SE/MSEP Only) (15) ......................................................................................................37

Auxiliary Chilled Water Control Valve (16)...................................................................................................37

Auxiliary Hot Water Control Valve (17)........................................................................................................38

Remote Air Condenser Enable Signal (18) ....................................................................................................38

Smart Pump Control Output (19)..................................................................................................................38

Remote Exhaust Fan Interlock (S Only) (20) ..................................................................................................38

Auxiliary Pool Water Heating System (21) ....................................................................................................38

Alarm Output (22).....................................................................................................................................39

Auxiliary Air Cooling System (23) ...............................................................................................................39

Auxiliary Air Heating System (24) ...............................................................................................................39

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Outside Air Temperature and Relative Humidity Sensor (25)...........................................................................39

Pool Water Piping and Installation...............................................................................................................40

PoolPak Pool Water Circulation Loop...........................................................................................................40

Auxiliary Water Heater (Field Supplied).......................................................................................................40

Main Pool Water Pump and PoolPak Pool Water Loop Pump Interlocks............................................................40

Pool Water Isolation Valves ........................................................................................................................40

Pool Water Pressure Transducer ..................................................................................................................40

Pool Water Piping Composition .................................................................................................................. 41

Freeze Protection....................................................................................................................................... 41

Condensate Drains....................................................................................................................................42

Condensate Drainage System Features ........................................................................................................42

Exceptions................................................................................................................................................42

Drain Trap Field Installation Instructions........................................................................................................42

Required Materials ....................................................................................................................................42

Remote Air Cooled Condenser....................................................................................................................44

Space and Location Requirements ...............................................................................................................44

Walls or Obstructions ................................................................................................................................44

Multiple Units............................................................................................................................................45

Units in Pits...............................................................................................................................................45

Decorative Fences .....................................................................................................................................45

Field Installed Piping..................................................................................................................................46

Piping Guidelines ......................................................................................................................................46

SECTION V: OPERATION ............................................................................................................ 50

CPCS Controller Operation ........................................................................................................................50

Remote Interface Unit (RIU) Features ............................................................................................................50

CPCS Controller Features ...........................................................................................................................51

Multi-Unit Network Operation ....................................................................................................................52

CM1 Network Configuration ......................................................................................................................52

RIU Network Configuration ........................................................................................................................52

Communications........................................................................................................................................53

Building Automation System (BAS) Connection..............................................................................................53

Virtual-Tech®Plus - REMOTE ACCESS PACKAGE(RAP) ...................................................................................53

Basic Controller Operation.........................................................................................................................53

Startup ....................................................................................................................................................53

Fault Condition .........................................................................................................................................54

Alarm Reset ..............................................................................................................................................54

Controller Navigation................................................................................................................................55

Main Menu ..............................................................................................................................................55

Status Screens...........................................................................................................................................55

Detailed Status..........................................................................................................................................56

Set Point...................................................................................................................................................58

Schedules.................................................................................................................................................59

Service ....................................................................................................................................................59

Input/Output Configuration ........................................................................................................................59

History.....................................................................................................................................................63

Unit Configuration .....................................................................................................................................65

Manual Mode...........................................................................................................................................71

Utilities.....................................................................................................................................................73

Airflow Balancing ..................................................................................................................................... 74

Overview ................................................................................................................................................. 74

Guidelines for Performing a Proper Airflow Balance...................................................................................... 74

Controller Adjustments ............................................................................................................................... 74

Troubleshooting......................................................................................................................................... 74

Overview ................................................................................................................................................. 74

System Status Information........................................................................................................................... 74

PoolPak®MPK Series IOM

AlarmName:............................................................................................................................................. 74

CprFaultName: ......................................................................................................................................... 76

SensorName:............................................................................................................................................77

Fault History Log .......................................................................................................................................78

Manual Mode...........................................................................................................................................78

Digital and Analog Input Configuration........................................................................................................78

Digital Input..............................................................................................................................................78

Analog Input.............................................................................................................................................78

Digital and Analog Output Configuration.....................................................................................................79

Digital Output...........................................................................................................................................79

Analog Output..........................................................................................................................................79

Startup & Warranty...................................................................................................................................79

Pre-startup ................................................................................................................................................79

Startup.....................................................................................................................................................79

Owner Training.........................................................................................................................................80

Warranty .................................................................................................................................................80

Maintenance ............................................................................................................................................80

Overview .................................................................................................................................................80

Daily Maintenance .................................................................................................................................... 81

Monthly Maintenance................................................................................................................................82

Semi-Annual Maintenance..........................................................................................................................83

Annual Maintenance .................................................................................................................................83

SECTION VI: WIRING ................................................................................................................. 84

Remote Connections Schematic...................................................................................................................84

Multiple Unit Control Schematic ..................................................................................................................85

MPK Field Wiring - Communications............................................................................................................85

MPK Field Wiring......................................................................................................................................86

Table 1-1. Typical Pool Water & Air Temperature Set-Points ..............................................................................9

Table 1-2. Recommended Pool Water Chemistry ...........................................................................................10

Table 3-1. MPK Unit Performance (at 82°F and 60% RH)................................................................................23

Table 3-2. MPK Factory Refrigerant Charge (lbs of R-410A)............................................................................23

Table 3-3. PoolPak Provided Remote ACC Specifications................................................................................24

Table 3-4. Remote Cooling Tower and Chilled Water Cabinet Dimensions .......................................................25

Table 3-5. Cooling Tower and Chilled Water Line Sizes.................................................................................26

Table 3-6. WCC Performance.....................................................................................................................26

Table 3-7. Pool Water Capacity ..................................................................................................................27

Table 3-8. PoolPak Gas Furnace Option ......................................................................................................28

Table 3-9. PoolPak Electric Heat Option .......................................................................................................28

Table 4-1. Pipe Sizes for Remote Refrigerant Condensers ...............................................................................47

Table 4-2. Remote ACC Refrigerant (R-410A) Charge ....................................................................................48

Table 4-3. Refrigerant (R-410A) Charge for Different Line Sizes.......................................................................48

Table 5-1. Pool Water Chemistry .................................................................................................................82

www.poolpak.com | 800-959-77256| MPK Series - Installation, Operation and Maintenance

Figure 2-1. Dewpoint Control Psychrometric .................................................................................................. 12

Figure 2-2. MPK System Schematic..............................................................................................................14

Figure 2-3. Active Airflow Control with Direct OA Measurement Schematic ......................................................16

Figure 3-1. MPK Dimensional Isometric View.................................................................................................22

Figure 3-2. Remote Cooling Tower Dimensions..............................................................................................25

Figure 4-1. Typical PoolPak Rooftop Installation.............................................................................................29

Figure 4-2. Single Point Power Supply..........................................................................................................32

Figure 4-3. Dual Point Power Supply............................................................................................................32

Figure 4-4. Remote Interface Mounting Plate ................................................................................................35

Figure 4-5. Pool Water Piping Schematic ..................................................................................................... 41

Figure 4-6. Negative Pressure Condensate Drain Piping Cross Section ............................................................43

Figure 4-7. Positive Pressure Condensate Drain Piping Cross Section................................................................43

Figure 4-8. Remote ACC Installation Clearances ...........................................................................................44

Figure 4-9. Remote ACC Installation Around Walls or Obstructions .................................................................44

Figure 4-10. Remote ACC Installation Clearances..........................................................................................45

Figure 4-11. Remote ACC Installation When Installing Units in Pits ...................................................................45

Figure 4-12. Remote ACC Installation When Installing Units Near Decorative Fences.........................................45

Figure 4-13. Remote ACC Above Unit ..........................................................................................................47

Figure 5-1. RIU Keypad ..............................................................................................................................50

Figure 5-2. CPCS Controller (CM1) Display .................................................................................................. 51

Figure 5-3. Startup Screen..........................................................................................................................53

Figure 5-4. Fault Condition Status Screen - Coil Freeze Warning.....................................................................54

Figure 5-5. Main Menu Screen ...................................................................................................................55

Figure 5-6. Status Screen 1: Return Air/Pool Status........................................................................................55

Figure 5-7. Detailed Status Screen 4: Airflow Status.......................................................................................56

Figure 5-8. Detailed Status Screen 5: Status Overview...................................................................................57

Figure 5-9. Detailed Status Screen 6: Operation Mode Stages........................................................................57

Figure 5-10. Detailed Status Screen 7: Fan Motor Status ................................................................................58

Figure 5-11. Detailed Status Screen 9: Compressor Module Status...................................................................58

Figure 5-12. Set Points Air Temperature Screen .............................................................................................58

Figure 5-13. Occupancy Schedule Screen ....................................................................................................59

Figure 5-14. Service - I/O Config screen......................................................................................................59

Figure 5-15. Digital Inputs - Smoke Purge screen............................................................................................59

Figure 5-16. Digital Outputs - Supply Fan screen ...........................................................................................60

Figure 5-17. Analog Inputs - Supply Air screen .............................................................................................. 61

Figure 5-18. Analog Outputs - Recirculation Damper Screen...........................................................................63

Figure 5-19. Fault Screen 1 – System Status Overview....................................................................................63

Figure 5-20. Fault Screen 2 – Airflow Status .................................................................................................64

Figure 5-21. Fault Screen 3 – Fan Currents ...................................................................................................64

Figure 5-22. Fault Screen 4 – Compressor Module 1 Fault Screen...................................................................64

Figure 5-23. Unit Configuration - Installed Features Menu...............................................................................65

Figure 5-24. Manual Mode Screen 1 - Overview ..........................................................................................71

Figure 5-25. Manual Mode Screen 4 - Airflow Control: Fan Speed (RPM) ........................................................72

Figure 5-26. Utilities Menu - Set Time and Date.............................................................................................73

Figure 6-1. PoolPak Control Panel................................................................................................................84

Figure 6-2. Multiple Unit Connection Schematic............................................................................................85

Figure 6-3. Field Wiring - Communications...................................................................................................85

Figure 6-4. MPK Field Wiring .....................................................................................................................86

PoolPak®MPK Series IOM

IMPORTANT

This product has been thoroughly tested before leaving the PoolPak factory.

However, please check at the earliest opportunity that the product has arrived in good condition and that no

damage occurred during shipping. If any damage is suspected, contact the carrier to file a claim.

If the product is to sit in storage for a length of time before installation, contact PoolPak Service department for

proper storage guidelines.

Warning

Only suitably qualified personnel who thoroughly understand the operation of this product and any associated

machinery should install, start-up or attempt maintenance of this product. Non-compliance 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 will perform startup and provide training for owner and site personnel.

PoolPak recommends that all troubleshooting, service, and maintenance be completed by an authorized service

technician for the best service experience with the equipment. If a labor or parts warranty claim is expected,

PoolPak service must be contacted before any work is to be performed. Refer to the standard PoolPak®MPK

warranty for complete details.

Intended Users

This manual is to be made available to all persons who are required to install, operate or service the product or any

other associated operation. Please ensure that a copy of this manual is presented to the end customer. Additional

copies of this manual are available on request and on the PoolPak website, www.PoolPak.com.

www.poolpak.com | 800-959-77258| MPK Series - Installation, Operation and Maintenance

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 difficult to control, and improper management usually results in an

uncomfortable environment, excessive operating costs and possibly serious structural damage. Effectively controlling

these special conditions requires 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 efficient 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.

PoolPak®MPK Series IOM

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 on the next page), which are present in

the water, become more concentrated in the air as the “water to air” interactions increase, affecting the indoor

air quality. A strong “chlorine” odor is an indicator of poor pool water chemistry, and is generally offensive to the

occupants. Higher levels of chloramines can cause skin/eye irritation and respiratory problems commonly known

as “lifeguard lung”. Most poolrooms are designed with a minimum ventilation rate to dilute the airborne pollutants

generated from the chemical interactions in the pool water. Typically these rates are based on ASHRAE standard

62.1 and dictated by local codes at about 0.5 CFM per square foot of pool and deck area, but depending on the

pool water chemistry the ventilation rate may not always be adequate for good poolroom indoor air quality.

However, increasing ventilation rates can significantly add to the cost of operation. Energy conservation strategies,

such as heat recovery, airflow measurement, and CO2 based ventilation control help control costs while improving

indoor air quality. Depending on the geographic location and season of the year, treating the outside air has a

direct effect on energy consumption. Some facilities prefer higher than minimum ventilation rates, up to 100% of

OA, to maximize indoor air quality, but the cost of treating this air can be significant.

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 difficulty 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. Here are some

recommended temperatures for poolrooms, which can be adjusted to meet specific needs of bathers. In general,

“active” poolrooms are maintained at lower temperature ranges so the users don’t overheat, warmer temperatures

are more common for seniors or children or less active pools.

The desirable humidity range is generally between 50 and 60% (see Table 1-1). Greater than 60% creates a sticky

feeling and/or difficult breathing. Low humidity results in evaporative cooling on the bather’s skin, resulting in a chill.

Poor air movement caused by improper duct placement within the poolroom will also lead to occupant discomfort.

Excessive supply air blowing on bathers can create drafts, while uneven air distribution may create stagnant zones

within the space.

POOL TYPE WATER TEMP (°F) AIR TEMP (°F) ROOM RH %

Recreational Pool 80 to 85 Water Temp + 2 55 to 60

Therapy Pool 86 to 92 86155 to 60

Whirlpools 99 to 104 86155 to 60

Table 1-1. Typical Pool Water & Air Temperature Set-Points

1Normally max 86°F to minimize overheating of occupants

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Pool Water Chemistry

Proper water chemistry (Table 1-2) 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 chloramine levels in the air. Not only does this have an effect on the water, but it affects the

bathers and the air they breathe.

Dehumidification/ventilation equipment is not designed to remedy the effects of poor pool chemistry, but is designed

to deliver prescribed ventilation to manage smaller amounts of pollutants generated from normal pool activity. Pool

water chemistry is a part of daily maintenance and it is recommended that the users follow the current National Spa

and Pool Institute standards. For more information, see the PoolPak®Educational Library article Indoor Pool Water

Chemistry.

POOL SPA

IDEAL MIN MAX IDEAL MIN MAX

Total Chlorine (ppm) 1.0 - 3.0 1 3 3.0 - 5.0 110

Free Chlorine (ppm) 1.0 - 3.0 1 3 3.0 - 5.0 110

Combined Chlorine (ppm) 0 0 0.3 0 0 0.3

Bromine (ppm) if applicable 2.0 - 4.0 2 4 3.0 - 5.0 210

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

Table 1-2. Recommended Pool Water Chemistry

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