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PoolPak PCP Series Operation And Maintenance Manual

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Summary of Contents for PoolPak PCP Series

  • Page 2 December 2024...

  • Page 3: Table Of Contents

    Table of Content General Information • Operating Safety • Reference and Additional Information Contact Us • Special Considerations for Equipment, Containing A2L Refrigerant • Basic Information Dehumidifier View and Options Dehumidifier External Systems Connection Dehumidifier Optional Arrangement Pool Water Heating Option – Bonding Air Conditioning Options –...

  • Page 4: General Information

    General Information This manual provides basic information about the applicable dehumidifier and its operation. This manual covers details of the equipment of various design, size, capacity etc.; therefore, some details • covered in this manual may not be relevant to each piece of equipment. Refer to your equipment’s submittal documentation.

  • Page 5: Reference And Additional Information

    Note CAUTION WARNING Indicates a situation that could Indicates a potentially hazardous Indicates a potentially hazardous result in equipment damage or situation which could result in situation which could result in improper/ineffective operation if serious injury or death if handled moderate injury or equipment handled improperly.

  • Page 6: Contact Us

    • Information and understanding of the explosion and ignition potential of FLAMMABLE REFRIGERANTS • Information about POTENTIAL IGNITION SOURCES, • Information about the ventilation of the equipment, its compartments and the room it’s installed in, and its effect on the safety (of the surroundings, carried out work tasks etc.) •...

  • Page 7: Special Considerations For Equipment, Containing A2L Refrigerant

    Special Considerations for Equipment, Containing A2L Refrigerant Attention: Equipment Containing A2L Refrigerant CAUTION! Dehumidifier, equipped with compressors, contains A2L (mildly flammable) group refrigerant. Such equipment placement shall satisfy certain requirements of local and national Codes and Regulations, such as UL 60335/SCA B52/ASHRAE 15 and others, as applicable. Review following chapter in detail prior to placement of the equipment to ensure the requirements are met.
  • Page 8 Table 2. Conditioned Space and Airflow Relationship Model PCP800-PCP1200 / PCP808 – PCP1212 Remote Remote Packaged Packaged Water/Fluid Water/Fluid AC option OACC OACC OACC OACC cooled cooled Pool Heating Option Mc, kg 13.7 12.8 QminTA, m3/h 1383.9 1295.8 456.8 368.7 TAmin, m2 41.9 39.3...
  • Page 9 Table 2 . Conditioned Space and Airflow Relationship (continued) Model PCP3000 / PCP3030 Remote Remote Packaged Packaged Water/Fluid Water/Fluid AC option OACC OACC OACC OACC cooled cooled Pool Heating Option Mc, kg 30.5 27.0 16.5 13.0 QminTA, m3/h 3089.9 2731.6 1673.8 1315.4 TAmin, m2...

  • Page 10: Basic Information

    Basic Information Dehumidifier View and Options Standard dehumidifier typically comes in various cabinet arrangements; general view and options are shown on Pic.C.1 (indoor option) and C.2 (indoor/outdoor option) respectively. Standard Composition: Return Air (RA) ductwork connection - • horizontal. • Supply Air (SA) ductwork connection options –...
  • Page 11 Vertical Composition Return Air (RA) ductwork connection - • horizontal. Supply Air (SA) ductwork connection • options – top, horizontal (left or right). • Outdoor Air (OA) intake - top Piping Connections ① Condensate Drain ② AC – Air-Cooled (refrigeration) ③...
  • Page 12 Horizontal Composition Return Air (RA) ductwork connection - • horizontal. • Supply Air (SA) ductwork connection options – top, bottom, horizontal (straight). • Outdoor Air (OA) intake ductwork connection options – top, horizontal. Piping Connections ① Condensate Drain ② AC – Air-Cooled (refrigeration) ③...
  • Page 13 Standard Composition Return Air (RA) ductwork connection • options – top, bottom, horizontal (end, sides). • Supply Air (SA) ductwork connection options – top, bottom, horizontal (sides). • Outdoor Air (min – OA, purge - POA) intake ductwork connection options – top, horizontal.

  • Page 14: Dehumidifier External Systems Connection

    Dehumidifier Options: Indoor/outdoor, single- or two-compressor dehumidifier. * • Airflow and ductwork connection options* (Return, Supply, Outdoor Air etc.) - see Pic. C.1 and C2. • “mirrored” cabinet arrangement (in reference to Return-Supply airflow direction) is also available in some models. Additional systems (Exhaust/Purge Fans, Heat Recovery etc.) are also available in some models.

  • Page 15: Dehumidifier Optional Arrangement

    Attention! Equipment Clearances and Dimensions! CAUTION! For equipment proper operation, maintenance and service, respective clearances should be maintained. Generally, 30” clearances to the equipment must be kept for the maintenance and service purposes. For the specific required clearances information, as well as dehumidifier overall dimensions, distances to pipe connections, duct connections etc., refer to the submittal documentation.
  • Page 16 Attention! Equipment Clearances! Proper clearances should be maintained for adequate airflow and heat rejection! Generally, up to 36” side and 96” top clearances are required. For more information on clearances as well as equipment dimensions and other details, refer to the submittal documentation. Pic.
  • Page 17 Pic. C.4-C December 2024...

  • Page 18: Equipment Specific Data

    Equipment Technical Data Detailed information about specific equipment is presented in submittal documentation; some general info is provided below: Air Data ESP Min 0.5” wc ESP Max 2” wc Leaving Air Temperature max 120 F Heating Water Data Pressure, MAX 250 psi Entering Water Temperature MAX 180 F...

  • Page 19: Layout And Components

    Layout and Components The general layout and components’ location is similar for all dehumidifiers; however, some may vary, based on the dehumidifier’s specific options and cabinet arrangement. Pictures below show all/most available options (D.1 – indoor options, D.2 – indoor/outdoor options respectively) – refer to submittal documentation for specific details. Dehumidifier Main Components Pic.
  • Page 20 Pic. D.1-B December 2024...
  • Page 21 Pic. D.1-C • Main Blower (1) is in the main blower compartment next to the Main Electric Panel (2) and Compressor Compartment (3). Min Outdoor Air (OA) Opening (4) is optionally equipped with a motorized damper and filter(s). The Manual •...
  • Page 22 Pic. D.2-A Indoor/outdoor rated model (shown on Pic. D.2) may come with some additional optional systems and components - refer to submittal documentation for specific details: • Depending on the dehumidifier model/composition: Gas Heater Package (12) could be located under the refrigeration coils’ deck or downstream of it. Package includes gas heater (61), gas heater electric and control panel (62) and provisions for combustion air intake (63) and flue exhaust (64).

  • Page 23: Control System

    Control System The dehumidifier control system is composed of sensors, spread throughout the dehumidifier, Main Control Board, Operator Panel and other electric components, located in the Main Electric Panel. Temperature Sensors (Pic. D.3-A): a) Temperature sensors (thermistors) are used to monitor various temperatures (air, water, compressor, etc.);...
  • Page 24 Pic. D.4-A • Dehumidifiers, containing A2L refrigerant, are equipped with Refrigerant Detection System (RDS) (30) - Refrigerant Sensor(s) (Pic.D.4-B), placed within compressor compartment to detect refrigerant leak and trigger mitigation measures (see chapter “Sequence of Operation” for more details). Refrigerant Sensor(s) exact location within the compressor compartment may vary per dehumidifier, dependent on its size and configuration, but typically sensors would be located closer to the floor/bottom of the equipment –...

  • Page 25: Outdoor Air Condensers And Fluid Coolers Layout And Components

    Outdoor Air Condensers and Fluid Coolers Layout and Components The general layout of AC options (air-and water-cooled) is shown on Pic.D.5 below with the outdoor air condenser (model NC-B-1, left) and fluid cooler (model NG-V-0, right) as an example. While layout and main components are similar for all applicable AC options, there are some deviations (number of fans, coil sizes, composition, etc.).
  • Page 26 • Pump (38) establishes glycol mixture circulation through the fluid cooler and dehumidifier; Expansion tank (39) compensates for temperature- • based glycol volume fluctuation; The pump package electrical sub-panel (40) contains the • pump package electrical power and control • The pump package manifolds are usually equipped with pressure gauges, automatic air venting valve, draining and other valves.

  • Page 27: Sequence Of Operation

    Sequence of Operation The dehumidifier’s ventilation system establishes the required airflow through the dehumidifier. The control system compares air temperature and humidity to their desired values (set points) and proceeds to dehumidify, cool or heat the recirculating air. If the dehumidifier is equipped with the pool water heating option, the pool water temperature is compared to its set point and pool heating is provided if required.

  • Page 28: Heat Recovery Option

    Heat Recovery Option. Dehumidifiers, packaged with Minimum Exhaust Fan and Minimum Outdoor Air damper, could also have additional Heat Recovery (HR) closed-loop glycol system. Heat Recovery loop (see Pic. E.1 below) consists of two coils (air-to-glycol heat exchangers) and a pump, establishing glycol circulation between them.

  • Page 29: Compressor(S)

    Compressor(s) Whenever the compressor operates, the evaporator is always dehumidifying and cooling the return air. The heat removed from the air at the evaporator, as well as the heat from the compressor's action, must be rejected to one of three heat sinks: room (premise) air, pool water (if applicable) or outdoors. The control system will direct the heat to where it is needed based on room (air and pool water temperature) conditions: •...

  • Page 30: A2L Refrigerant Mitigation

    Outdoor Condenser and Fluid Cooler Operation. Based on the type of the outdoor condenser or fluid cooler fans’ type (two-speed fans or EC-type/modulating fans), respective signal(s) are sent by control system to engage said fan(s): for two-speed fans - on/off signals (switching speeds, based on compressor head pressure level), for EC-type fans - variable 0-10VDC signal (proportional to the compressor head pressure level).

  • Page 31: Interface And Communication

    Interface and Communication Touch Display Operator Panel The Touch Display Operator Panel (OP), shown on Pic. F.1, is used as a main interface between the dehumidifier and operator. The same OP can be located in the dehumidifier main electric panel (default; used as a local OP) or installed remotely from the dehumidifier •...

  • Page 32: Alarms

    Alarms If the dehumidifier control system detects abnormal or unsafe for further operation situation, it issues Alarm (notification of such situation accompanied by respective component or entire dehumidifier stoppage and/or lockout) or Alert (notification of minor abnormal situation without any devices’ stoppage or lockout). All alarms and alerts are recorded and can be viewed/cleared via the Touch Display OP: ...

  • Page 33: Remote Communication

    Remote Communication Although dehumidifier is designed to operate as a self-controlled device (not requiring any external control), communication between the dehumidifier and external control and monitoring systems is possible. WebSentry WebSentry is an online tool (also referred to as Web Monitor), that allows for remote communication to the dehumidifier for various purposes such as monitoring, data collection, parameters adjustment, and notifications.

  • Page 34: General Considerations For Any Work, Performed On The Equipment

    General Considerations for any Work, Performed on the Equipment Whether performing routine, day-to-day maintenance or one-off (commissioning, repair etc.) work tasks, one must recognize potential hazards, associated with the task to be performed, equipment and its installation specifics, as well as be properly trained and qualified to perform such tasks (for training and qualification requirements – refer to chapter “Personnel Training and Qualification”).
  • Page 35 Machinery room shall be of a tight construction and not accessible to general public.  Machinery room with equipment that contains A2L refrigerant shall:  • be mechanically vented outdoors be equipped with refrigerant detection system • have NO flame-producing devices or hot surfaces permanently installed in the room •...

  • Page 36: Basic Maintenance

    Basic Maintenance Although dehumidifier is built for minimal service downtime, periodic preventative maintenance is required to ensure maximum reliability, safety, and operating efficiency. WARNING! To ensure equipment longevity and proper and efficient operation, the dehumidifier and its auxiliary systems and devices (outdoor condenser, fluid cooler, boiler package, etc.) must be maintained properly and regularly.

  • Page 37: Routine Maintenance Program

    Routine Maintenance Program Creating facility-specific routine maintenance program and following it is vital to equipment longevity and efficient operation. The suggested general maintenance operations and their frequency/intervals, listed in the table M-1 below, can be used to create such a program. For more detailed maintenance recommendations related to specific components, refer to the respective component manufacturer’s manual.
  • Page 38 RDS Sensor (Equipment with A2L refrigerant) Refrigerant sensor, installed within the dehumidifier, does not require any specific maintenance. Used sensor has long-life expectancy and not required to be replaced on regular basis. Failed sensor should be replaced with the same type/brand; consult equipment manufacturer before replacing sensor with different type/brand.
  • Page 39 Special Maintenance Tasks. Fluid Cooler Winterization. Normally fluid coolers are used in the systems, filled with glycol mixture to prevent the system and the fluid cooler from freezing and, potentially, rupturing, when exposed to temperatures below freezing point. When fluid cooler is used with media that, when exposed to low temperatures, could freeze (water or lower- percentage glycol mixture), one way to protect the equipment is to drain it (also known as “winterization”...

  • Page 40: Service, Repair, Commissioning And Decommissioning

    Service, Repair, Commissioning and Decommissioning WARNING! Review and follow details in chapter “Work Tasks and Safety – General Considerations” in addition to current chapter to ensure safety of performed tasks! In some instances, more intrusive/specific work tasks (apart from routine maintenance) required. Apart from standard best field practices and Codes and regulations, applicable to respective tasks, it is critical to consider some equipment and its installation-specific details.
  • Page 41 – that capacitors are discharged: this shall be done in a safe manner to avoid possibility of sparking; – that no live electrical components and wiring are exposed while charging, recovering or purging the system. – that there is continuity of earth bonding •...
  • Page 42 A2L Refrigerant Leak Detection Methods. WARNING! It is prohibited to use potential sources of ignition to search for refrigerant or for detection of refrigerant leaks! A halide torch (or any other detector using a naked flame) shall not be Acceptable (for A2L refrigerant) leak detection methods include: •...
  • Page 43 • Before attempting the procedure, ensure that: • system is isolated electrically; • area is well ventilated • mechanical handling equipment is available, if required, for handling refrigerant cylinders; • all personal protective equipment is available and being used correctly; •...

  • Page 44: Warranty

    Email: Warranty@DehumidifiedAirServices.com PoolPak warrants as set forth and for the time periods shown below that it will provide through either a DASV Service Technician or an authorized service organization specified and approved by DASV, a new or rebuilt part to replace a factory installed part which has failed because of defect in workmanship or material.
  • Page 45 Replacement Part Warranty If a replacement part provided by PoolPak under this warranty fails due to a material defect prior to the end of the Two-Year Parts Warranty (or the end of the extended warranty period if applicable), whichever comes first, PoolPak will provide a new or rebuilt part F.O.B.
  • Page 46 2. Optional Five-Year Dehumidifier Coil Warranty Subject to the terms above, PoolPak will provide a replacement coil for up to 60 months from the date of the warranty activation. Extended coil warranties are for parts of the dehumidifier only and does not cover parts of dry cooler or OACC coils.

This manual is also suitable for:

Pcp800Pcp1200Pcp808Pcp1212Pcp1400Pcp1414 ... Show all

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