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PoolPak PCP Series Installation Manual

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  • Page 2: Table Of Contents

    Table of Contents General Information ............................3 Operating Safety (Warnings, Cautions, and Notes) ....................3 Reference and Additional Information ........................4 Delivery and Storage............................7 Receiving Checklist ..............................7 Shipping Damage Handling ............................7 Storage ..................................8 Mechanical Installation ............................9 Lifting and Rigging ..............................

  • Page 3: General Information

    General Information This manual provides basic information about various installation aspects of the applicable equipment and its additional and auxiliary systems and devices. This manual covers installation 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 4 Reference and Additional Information For safe, efficient and problem-free operation, it is critical to handle the dehumidifier (as well as related systems and components) properly at each step - from receiving and storage to installation and start up. Relevant information can be found in the respective documents (Operation and Maintenance Manual, Start Up Package, etc.) provided with the dehumidifier.
  • Page 5 In addition to qualifications outlined above, for personnel, performing some INSTALLATION, SERVICE, REPAIR and DECOMMISSIONING tasks (related to install, repair and/or disposal of mechanical and refrigeration equipment, ductwork, piping, electrical), formal training in respective field and/or trade licensing, issued by local or national authorities may be required.

  • Page 6: Delivery And Storage

    Delivery and Storage. Receiving Checklist Each piece of equipment is tested and inspected before it ships from the factory; however, the equipment may suffer damage in transit. It is highly recommended to thoroughly check for both visible and concealed damage upon the equipment arrival and before signing the receiving papers: ...

  • Page 7: Storage

    Storage • Protection from the elements is required for any equipment that will be stored on a job site or holding area before installation. • For long-term storage, a controlled indoor environment is highly recommended. • All factory-applied shipping protection should be removed before the equipment is put into storage. Shipping protection material is provided by the factory for shipping only –...

  • Page 8: Mechanical Installation

    Mechanical Installation WARNING! All work must be done by qualified personnel in accordance with local and national Codes, Standards and Regulations as well as respective submittal documentation and manufacturer recommendations. CAUTION! Obtain all necessary documentation (manufacturer documentation, submittal documentation, drawings, etc.) and familiarise yourself with it before performing installation or any other related tasks. Lifting and Rigging WARNING! Lifting and rigging must be done by trained professionals in accordance with proper lifting...

  • Page 9: General Mechanical Installation Requirements

    General Mechanical Installation Requirements WARNING! The equipment shall be NOT accessible to general public! Attention: Installing Contractors CAUTION! Dehumidifier, containing A2L (mildly flammable) group refrigerant, shall comply with minimum requirement for airflow and conditioned space area – refer to Table 1 and Table2 of Operation and Maintenance manual! Ensure that this is the case prior to installing the equipment! NOTE.
  • Page 10 Indoor Dehumidifier Installation (dehumidifier, installed in mechanical room) Mechanical room, where dehumidifier is installed, and dehumidifier installation must comply with requirement CSA B52/ASHRAE 15 for MACHINERY ROOMS. Requirements include, but not limited to, following:  Machinery room shall be of a tight construction and not accessible to general public. ...
  • Page 11  Uncrate/unwrap provided louver and place it over respective opening/damper (Pic. E.3): Larger louvers require two persons to lift and place the louver Dehumidifier with larger louvers also have louver support lip over the damper.  Adjust louver position – shift it slightly left or right as needed to ensure louver side walls and access panels do not interfere with damper linkage, actuators, filter racks, sensors, etc.
  • Page 12 Outdoor Dehumidifier – Outdoor Air and Exhaust “Door/Louver” Assembly Installation For shipping purposes, the OA and Exhaust Louver(s) may be shipped on the top of the dehumidifier and will require field installation (see Pic. E.5). This normally applies to outdoor NE004-NE008 series dehumidifiers. ...

  • Page 13: Outdoor Condenser (Oacc) And Fluid Cooler (Oafc) Mechanical Installation

    Outdoor Condenser (OACC) and Fluid Cooler (OAFC) Mechanical Installation The requirements outlined in General Placement of the Equipment (see above) apply to all models of OACC/OAFC.  It is recommended to anchor light-weighted OACC/OAFC to the horizontal mounted surface (concrete pad etc.). This applies to all OACC models and some OAFC models (NG-V-01, -02, -11 and -12).
  • Page 14  OACC model NC-B assembly is shown on Pic. E.7B below: Uncrate/unwrap the condenser and mounting kit. Assemble left and right mount legs as shown with provided bolts, nuts, and washers (except for joint point (a) – it must be bolted to the condenser) Align holes (a) and (b) in the mount legs with the holes in the condenser and attach them with provided bolts, nuts and washers.
  • Page 15 NC-Z Pic. E.7C ATTENTION! Cooling Fluid Lines Sweating! Under certain conditions (namely – when the cooling fluid lines’ outer surface drops below dew point of the surrounding air, particularly inside the facility), said lines may “sweat” as condensation forms on their surface. Should this occur, it is recommended to insulate the piping to prevent condensation.

  • Page 16: Mechanical Installation - Special Cases

    Mechanical Installation – Special Cases Some equipment may have additional/optional arrangements – refer to submittal documentation and equipment accompanying factory instructions. Frame-mounted main blower shipping brackets. For shipping purposes, larger (7 HP and up) direct-driven main blower frame springs are affixed with shipping brackets (see Pic.
  • Page 17 “Split-Deck” dehumidifier (“Double-Decker”) – mechanical field disassembly and assembly If requested, “Double-decker” (stacked) dehumidifiers are provided with means for site disassembly (splitting top deck from the bottom for shipping/delivery purposes) and assembly afterwards. Refer to Disassembly and assembly Instructions, provided with the dehumidifier! CAUTION! Before removing top deck from the bottom, ensure that ALL other system connections...
  • Page 18 “Split-Cut” dehumidifier – mechanical field assembly Under special conditions, the dehumidifier may be split into two or more sections to ease the installation and delivery process. Refer to the dehumidifier submittal drawings and Disassembly and Assembly Instructions, provided with the dehumidifier (instructions include mechanical, piping, and electrical guidance for reassembly). WARNING! DO NOT lift assembled dehumidifier.

  • Page 19: Ductwork Connection

    Ductwork Connection WARNING! All work must be done by qualified personnel in accordance with local and national Codes, Standards and Regulations as well as respective submittal documentation and manufacturer recommendations. CAUTION! Obtain all necessary documentation (manufacturer documentation, submittal documentation, drawings etc.) and familiarise yourself with it before performing installation or any other related tasks. Refer to dehumidifier submittal drawings for location and size of dehumidifier duct connections.

  • Page 20: Duct Connection - General Considerations

     Maintain the required minimum OA intake along with negative pressure in the space (respective Exhaust Fan and OA intake arrangement)  Where/if applicable, establish direct exhaust of humid/chemical laden air from the source (locate exhaust grille above/close to spa, whirlpool, etc.). ...

  • Page 21: Piping Connection

     follow said space heater manufacturer installation instructions (duct transitions, distances, clearances, support, direction, etc.), respective local codes and regulations and standard field practices.  Install space heater in the supply duct, downstream of the dehumidifier.  It is recommended for the space heater to be controlled by the dehumidifier control system (for efficient operation and air temperature maintenance).

  • Page 22: Pool Water Heating Piping

    P-trap installation: Make sure that each drain connection has a P-trap Make sure that there is only one P-trap installed (do not double-trap). If soft piping material is used (braided hose, etc.) - ensure the drain line is not sagging (this may create “double-trapping effect”...

  • Page 23: Refrigeration Piping

     Auxilliary pump or main pool pump must be located upstream of (before) the dehumidifier. The dehumidifier normally requires constant waterflow through (to ensure proper automatic control over pool heating feature); however, if requested, it could be equipped with means to control auxiliary pump.
  • Page 24 Line Set Selection and Sizing Refer to dehumidifier and/or condenser main labels for line set sizing (both, max line set length and pipes’ • diameters): note that line set pipe diameters may differ from respective piping connections size at the dehumidifier and condenser –...
  • Page 25 Pressure/Leak Testing. Leak Detection. Refrigeration piping circuit must be leak-free to ensure problem-free operation of the equipment, comply with environmental and safety requirements. Following tasks to ensure that must be performed at different stages of piping. After completion of field piping for split systems, the field pipework shall be PRESSURE TESTED with an inert gas and then vacuum tested prior to refrigerant charging.
  • Page 26 To determine the field charge, calculate the pipe line set charge by multiplying its length by  the charge-per-foot amount show on the main lable, and then add to it OACC charge amount, shown on the main lable as well. Use ball valve access port(s) or additionally installed access port(s) on the line set for charging.
  • Page 27 Pic.G.4b December, 2024 Dehumidifier Install Manual...

  • Page 28: Fluid Cooler Piping (Ng Models)

    Fluid Cooler Piping (NG models) Line Set Selection and Sizing Refer to dehumidifier and/or fluid cooler main labels for line set typical diameter (both lines, supply and return, • are normally of the same size); note that size may differ from respective piping connections size at the dehumidifier and fluid cooler.
  • Page 29 Pressure Testing and Charging Refer to the fluid cooler and/or dehumidifier’s main label and • submittal documentation for operating pressure and cooling media selection. Typically, mixture of food grade propylene glycol (with rust inhibitors added) and distilled water is used as a cooling fluid.

  • Page 30: Other Piping Systems And Special Cases

    Other Piping Systems and Special Cases Space Heating and Space Cooling Hydronic Systems Requirements, outlined in Piping Connection General Considerations (see above), apply to all types of space heating and/or space cooling fluid systems (water, glycol, etc.) – refer to respective piping termination labels (IN/OUT), main label (for line sizing) etc.
  • Page 31 Refrigeration circuits, depending on dehumidifier type, size and number of splits/sections,  could be provided completely empty or partially charged: be aware of refrigerant content in the circuits and the way circuits were split at the factory. Typically, if the dehumidifier is partially charged (normally, NP series): ...

  • Page 32: Electric Connection: Power, Control And Communication

    Electric Connection: power, control and communication WARNING! All work must be done by qualified/licenced personnel in accordance with local and national Codes, Standards and Regulations as well as proper field practices, respective submittal documentation and manufacturer recommendations. CAUTION! When connecting the electrical power supply and/or control wiring, refer to equipment submittal documentation, wiring diagrams and equipment labels and stickers to identify proper electrical/connection panels, access points, connection terminals etc.

  • Page 33: Equipment Main Power Connection

    Equipment Main Power Connection Main (‘high”) power is to be brought to equipment main PDB (power distribution block, see Pic. H.1 (b)), located in the main electric panel – refer to equipment labels and manual for panel and PDB location reference. If equipment has a disconnect, power must be brought there (Pic.

  • Page 34: Field Wiring - External Control And Communication

    Field Wiring – External Control and Communication Although normally dehumidifier is provided with all sensors and control devices, required for its operation, installed and pre-wired from factory, various external devices and systems could be also connected to the dehumidifier control system. •...
  • Page 35 socket (see Pic. H.3); this RJ-45 socket is internally connected to same serial port as pins 6 (485+) and 7 (485-) on the board terminal JCOM. NOTE: It is not recommended to have multiple devices (Ops, etc.) connected to the same serial port; do not •...
  • Page 36 Other end could be connected directly to a network switch, router or wireless Access Point (providing WiFi • connection to the local network). Certain configuration of dehumidifier control software and local network settings may be required – refer to WebSentry Installation Guide document and other related documents; contact the factory as needed. BACnet Currently, three BACnet protocols are supported: BACnet Over Ethernet, BACnet IP, and BACnet MSTP.
  • Page 37 Table H.2 Gateway pin JCOM pin Function Power connector 24VDC power (24+) 24VDC common (DCC) RS232/422/485 connector Serial port 232 (RX) Serial port 232 (TX) 24VDC common (DCC) Pic.H.5 Certain configuration of dehumidifier control software, LON-based BMS and local network settings may be required to establish proper communication, access desired parameters/points, etc.–...
  • Page 38 Electrical Reassembly Once the dehumidifier is installed and decks are reassembled, reinstall control and power wiring. • Pull wires back into bottom deck and install into respective pins/terminals; refer to wires tags, dehumidifier wiring diagram and wiring diagram legend. “Split-Cut” dehumidifier – electrical field assembly. Each “split-cut”...

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