S E R I E S
1420 Stoneridge Drive, Suite C
Middletown, Pennsylvania 17057
Toll: 800-753-9633
Phone: 717-902-1923
Fax: 717-902-1933
500i Series Design &
Installation Guide
5 0 0 i
April 2015
REV 1.8
4-28-15
HydroWorx International, Inc.
HydroWorx is a registered trademark of
HydroWorx International, Inc. Patents Pending
Contact
Information
HydroWorx International Inc.
1420 Stoneridge Drive, Suite C
Middletown, Pennsylvania 17057
www.hydroworx.com
Toll Free: (800) 753-9633
Phone: (717) 902-1923
Fax: (717) 902-1933
Table of Contents
General Design Information
1-3
Typical Contractor Installation Scope-of-Work
3-8
Design & Construction Checklist
9-10
Warranty Documents
Drawings:
Pool room Layout
Rough Opening
Mechanical Pit Layouts
Housekeeping Pad Layout
Equipment Keep Outs
Section Views
Maintenance System Suction Plumbing
Maintenance System Return Plumbing
Therapy Jet Suction Plumbing
Therapy Jet Return Plumbing
Adjustable Water Depth Plumbing
Electrical
Optional Video & Control Layout
Product Description
The HydroWorx 500i Series pool is a one-piece acrylic design with a fiberglass reinforced shell,
resistance jets and an underwater treadmill. The 500i Series pool may be installed above ground,
partially in-ground, or fully in-ground. The mechanical and electrical pool components are typically
located below the floor surface in the lower level mechanical room or in an adjacent equipment room
while not exceeding maximum distances of external pool equipment detailed in this installation guide.
As regulatory and code requirements vary significantly from State to State and even between local
jurisdictional agencies, permitting and compliance with State and local provisions relative to health,
pool/spa, building, electrical, plumbing , mechanical, safety, etc. is the responsibility of the owner.
It is critical that the owner and/or their authorized design representative consult with the agencies
having jurisdiction to ensure compliance with applicable regulatory and code requirements.
Contact HydroWorx immediately should regulatory or code circumstances arise.
Access & Serviceability
Recommended minimum architectural, structural, mechanical, electrical, and plumbing design criteria
identified in this Design and Installation Guide must be maintained for future serviceability of the pool.
Any design that does not meet the minimum requirements must be approved by HydroWorx.
Site Preparation
The owner’s pool contractor is responsible for preparation of the site prior to delivery. The mechanical
pit and pool room structures, including all utilities (power, water, sanitary, etc.) required for pool
operation shall be designed and installed by the owner’s pool contractor. For more details about pool
requirements, please refer to the subsequent technical specifications.
Pool Room
The water treatment area of this HydroWorx pool is designed to accommodate from one (1) to five (5)
patients/athletes during treatment sessions in the 7’-6” by 14’-0” area. The recommended minimum
dimensions for the pool room are 12’ wide by 22’ long by 10’ high allowing adequate installation and
deck space around the pool. Additional space may be required for: dehumidification systems,
cabinetry, storage, showers, changing rooms, etc.
Floor or perimeter drains must be incorporated into the design of the pool area. If floor drains are
chosen, several should be placed around the pool with special attention to the high traffic areas. The
finished floor MUST be flat/level, smooth, and consistent at all edges of the rough opening. The pool
room floor should slope away from walls towards the floor drains while maintaining a 6” level setback
from the pools rough opening.
Adequate airflow, temperature control, and dehumidification in the pool room is required primarily to
maintain a comfortable temperature for the occupants, and to protect against adverse conditions
inherent with a humid environment. The pool has a surface area of 95 ft2 and the water is generally
kept between 92-94 degrees Fahrenheit. Pool rooms are typically kept at 85 degrees Fahrenheit to
keep the variance between the pool water and the ambient air temperature at a minimum. The
Page 1
anticipated daily pool evaporation rate under these conditions is approximately 15-20 gallons per day.
Check with jurisdictional code requirements for minimum air exchange and humidity requirements.
This unit may include an optional underwater video monitoring system. When selected, the pool room
design must include cabinetry located in front of the pool to accommodate these components.
Mechanical Pit
The mechanical pit design must include adequate unobstructed access to the pool shell, accessory
equipment (filter, pumps, heater, etc.), and the electrical control panel. Recommended minimum
dimensions for the mechanical pit are shown in the enclosed drawings and it is important to verify if
the optional variable water depth system with holding tank was purchased / this will INCREASE
the required minimum dimensions of the mechanical pit. The design must also include HVAC
controls appropriate for the area, lighting, and a sump pump or drains. ALL of the HydroWorx 500i
external equipment detailed in the Mechanical Pit Layout Drawing is TYPICALLY located in the
HydroWorx mechanical pit as detailed in this Design and Installation Guide. Maximum distance
from the pool for locating HydroWorx external equipment is 25 feet and MUST be approved by
HydroWorx.
The structural weight of the pool is 1,300 pounds, the water weight of 2,000 gallons is 16,700 pounds,
and the total weight is 18,000 pounds. This weight will be bearing on the mechanical pit floor;
therefore a structural engineer should be consulted to determine structural requirements for the floor.
The required vertical distance from the mechanical pit floor to the pool room FINISHED floor is 5’-2”.
The mechanical pit floor below the pool must be constructed to very tight tolerances. The floor must
be level, with less than 1/8” variance over 10’, as measured with a straightedge. The floor must be
hard-troweled and finished smooth, not left rough as is commonly done in mechanical rooms. Any
slope to the mechanical pit floor must take place outside the foot print of the HydroWorx pool and
treadmill motor location.
The HydroWorx pool is drained via gravity by means of 2” PVC drains installed at the lowest point of
the pool-shell side wall. The pool drain shall be connected into the customer-supplied sump pit so the
water can be discharged during normal maintenance and as necessary for operational demands of the
owner. The sump pit or gravity drain selected by the owners design professionals must be sized to
handle a minimum of 60 GMP. The HydroWorx maintenance pump CANNOT be used to drain
the pool or it will void its warranty.
The mechanical pit should be designed to maintain an ambient temperature typical for mechanical
room occupancy (79º - 83º F) during maintenance of the pool equipment. The information below may
be utilized for heat discharge in determining the appropriate HVAC design for the mechanical pit. The
HydroWorx 500i Series therapy pool, fully equipped, includes the following:
1 - 11 kW electric heater
1 - 4 HP front therapy jet pump (10,186 BTU/hr)
1 - 5 HP treadmill motor (12,734 BTU/hr)
1 - ¾ HP maintenance circulation pump (1,910 BTU/hr)
1 - 2 HP optional side jet pump (5,094 BTU/hr)
2 - 2 HP optional water depth transfer pumps (2 x 5,094 BTU/hr)
Page 2
Utilities
Water Supply: The owner shall provide a minimum 2” diameter water supply line with anti-siphon
device connected to the circulation return line and a ¾” diameter hose bib with anti-siphon device in
the pool room.
Electrical Service: The owner shall provide an electrical service designed for the HydroWorx control
panel requirements which is:
Standard: 120/208-240 volt, 100 amp, 3-phase, 5-wire configuration (L1, L2, L3, ground, neutral)
Sanitary: The owner shall provide a sump pit with pump or floor drains for connection to the pool’s
maintenance system and main drain. The sanitary system should be designed to accommodate 2,000
gallons via gravity through a 2” PVC pipe. 60 GPM draining capacity in the HydroWorx mechanical
space is the acceptable minimum. The HydroWorx maintenance pump CANNOT be used to drain the
pool or it will void the components warranty.
Typical Scope-of-Work Necessary to Install a HydroWorx Pool
Typical General Contractor Scope-of-Work:
Construct the pool room and mechanical pit per the owner’s design documents and in accordance with
this HydroWorx Design & Installation Guide.
The construction sequence must consider the opening necessary to deliver the ONE PIECE pool shell
into the pool room. The pool shell is a 7’-6” wide by 14’ long by 5’-5” high rigid fiberglass unit with
an acrylic finish. A minimum 8’ wide by 6' high path from the anticipated off-loading point into the
pool room must remain until such time that the pool is delivered. The pool must remain upright at all
times during delivery to avoid damaging the integrated treadmill and the pool shell. The pool cannot
be turned on its side.
General contractor is responsible for receiving and unloading the pool components and equipment
based on the delivery date noted on the Delivery Confirmation Form.
The pool will be delivered on a flatbed truck to the project site and it is the general contractors
responsibility to unload and set the pool into its final location and set the external pool equipment in
the mechanical space per the equipment layout. The pool will be wrapped with heavy duty shrink wrap
and include load hugger rigging straps creating a central pick point for moving the pool into final place
in the pool room. Below you will see a picture of the typical rigging method to offload where a forklift
/ lull with a minimum 6 foot fork extensions are used and an additional picture showing the pool being
rigged using a gantry crane to lower it down into the mechanical space. A gantry crane can be rented
from a rigging company such as Lifting Gear Hire (800-878-7305).
Page 3
Following placement of shell in the rough opening, level the pool shell with the leveling jacks (see
photo #5) and support the steps utilizing concrete block (see photo #2). Spray foam should be used
between the block and steps as shown. A structural support is required (pressure treated wood is
typical) must also be installed under the platform in the cavity between the rear platform and the
mechanical pit floor (see photo #1). See the enclosed drawing for block and support locations.
#1
#2
Page 4
Shim the wooden supports as necessary to level the pool side to side and front to back. These shims
should be checked once the pool is filled with water. Install the provided angle brackets to floor at the
ends of the wooden support (see photo #3 & 6). Foam should be added underneath the 500 to fill any
voids or unevenness (see photo #4). The leveling jacks can be lowered at this point.
#4
#3
#5
#6
Anchor the treadmill motor base and connect the treadmill shaft to the treadmill motor via the treadmill
belt. See treadmill motor connection sheet for installation details.
The 500i Series pool will ship with a NSF-approved skimmer at the rear of the pool requiring a bump
out in the floor as shown below. There are several methods to finish the floor around the skimmer such
as a removable stainless steel plate, but the skimmer will need to have top access and be able to
support patients/athletes above.
Page 5
Protect the pool throughout the duration of construction by constructing a temporary work platform
over the unit. The platform shall be constructed of floor joists and plywood decking covered with a
tarp to prevent water and construction debris from entering the pool and mechanical pit thereby
damaging the pool and its components. There can be no standing water in the mechanical pit at
anytime and the protective platform CANNOT come in contact with the acrylic pool shell.
If the optional video package is chosen, provide a 3” diameter opening/chase / straight pipe or long
sweep (no 90’s) dedicated solely for HydroWorx low voltage control cables from the mechanical pit
into the pool room, in close proximity to the pools video monitoring system typically located centered
on the wall on the front side of the pool / front of the HydroWorx pool is the end where the underwater
treadmill is located. This must be a dedicated chase / sleeve for the HydroWorx cabling and no other
equipment can be run in this chase / sleeve.
Upon completion of the electrical and plumbing requirements, clean and fill the pool and complete the
site analysis checklist procedures necessary to place the pool in service. This form must be
completed and returned to HydroWorx before the customer in-service training can be scheduled.
Typical Mechanical Contractor Scope-of-Work:
Provide all labor, materials, and equipment required by the owner’s contract documents and as needed
to accommodate the conditions identified in the HydroWorx Design & Installation Guide and per the
designer’s documents for adequate heating, ventilation, air conditioning, and dehumidification of the
pool room and mechanical pit. The mechanical contractor is responsible for installing the properly
sized ventilation and humidity control unit. This is to ensure the mechanical pit temperature does not
rise above 85 degrees Fahrenheit with the respective heat loads for the pool equipment only. Careful
heat load calculations should also be considered for all other disciplines related to the mechanical pit.
Adequate airflow, temperature control, and dehumidification in the pool room is required primarily to
maintain a comfortable temperature for the occupants, and to protect against adverse conditions
inherent with a humid environment. The pool has a surface area of 95 ft2 and the water is generally
kept between 92-94 degrees Fahrenheit. Pool rooms are typically kept at 85 degrees Fahrenheit to
keep the variance between the pool water and the ambient air temperature at a minimum. The
anticipated daily pool evaporation rate under these conditions is approximately 15-20 gallons per day.
Check with jurisdictional code requirements for minimum air exchange and humidity requirements.
Page 6
Typical Electrical Contractor Scope-of-Work:
Provide and connect a 120/208 volt, 100 amp, 3-phase, 5-wire configuration (L1, L2, L3, ground,
neutral), to the HydroWorx control panel. Refer to the electrical schematic for wiring requirements
and the panel manufacturer wiring diagram located inside the HydroWorx control panel.
Install metal conduit and wire as required by code from the HydroWorx control panel and terminate
the feed to each of the following pool components:
1 - 11 kW heater
1 - 5 HP treadmill drive motor
1 - 4 HP front jet pump
1 - ¾ HP maintenance pump
1 - 2 HP side jet pump (optional)
2 - Non-GFCI underwater video camera receptacles when option selected
2 – 2 HP optional adjustable water depth transfer pumps
Install the HydroWorx supplied low voltage cables as required by code to the following pool
components:
•
•
•
•
•
25-pin connector cable from HydroWorx control panel to the HydroWorx pendant
Category 5 cable from the HydroWorx control panel to the HydroWorx computer
Adjustable water depth level sensors from the HydroWorx control panel to the
pool site tube and the water storage tank site tube. (when option selected)
Set up the computer and connect the cables as required to start up the pool.
RCA video cable from underwater cameras to the underwater video system
switcher box (when option selected)
Provide all labor, materials and equipment necessary to install interconnecting electrical conduit and
wiring between each HydroWorx pool component and the HydroWorx control panel as required by the
owner’s design documents and in accordance with this Installation Guide.
Wall mount provided electrical panel off the floor meeting any local code requirements. See the
electrical manual for dimensions of the panel.
Unless otherwise required by code, all of the wiring for the devices listed should be enclosed in the
appropriate size metal conduit and terminated at the device with (3) feet of flexible Liquidtite conduit.
Metal conduit is required to reduce motor noise and GFCI nuisance tripping. All conduit entry points
must be sealed with UL Listed sealing device. Each motor requires a separate conduit run.
All pool equipment must be bonded with a bonding wire including the treadmill. The treadmill has a
bonding wire pre-installed to connect in. See the photos below for reference. Gauge of the ground
wire of any appliance must be as large as the hot wire(s) so it is capable of efficiently conducting
electricity away from the device in the event of a short circuit or stray current, as well as prevent
GFCI nuisance tripping.
Page 7
TREADMILL
BONDING
Use at least 75°C stranded copper MTW or THHN wire of proper size (refer to electrical schematic)
when installing field wiring - DO NOT use solid wire or Romex.
Prior to connection to the HydroWorx Control Panel(s), check the voltage at each leg of the 100 amp,
3-phase service feed.
Prior to filling the pool with water, check rotation of all pumps and test pool electrical components.
Electrical Components Installation & Maintenance Inspection Checklists and Warranty
Activation Forms
Please reference the electrical installation checklists included in this Installation Guide for items to be
completed by the projects qualified licensed electrician upon installation and recommended follow-up
yearly inspections. These checklists are critical to ensure installation meets the proper specifications
of all referenced manufacturers and the owner should request copies of all completed forms from
the electrical contractor before allowing the HydroWorx pool(s) to be used. At a minimum, yearly
inspections should be performed by a qualified licensed electrician to re-inspect all items noted on
the checklists to ensure ongoing compliance.
The documents included in this Installation Guide are the following:
ISTECH Warranty Activation Form
•
This is the form that comes with every ISTECH electrical panel that must be completed and
faxed or mailed to ISTECH to activate warranty on the electrical panel and confirm the unit is installed
per the original manufacturer’s guidelines. This is the main power panel that controls functions on the
HydroWorx pool on the following pool models: 2000, 1200, 3500, 3500i, 750, 750i, 500, 500i, LSeries, T-Series.
Coates Heaters Installation & Maintenance Inspections Checklist
Page 8
•
This form must be completed to confirm the unit is installed per the original manufacturer’s
guidelines. This is the unit that provides heat to the HydroWorx pool on the following pool models:
2000, 1200, 3500, 3500i, 750, 750i, 500, 500i, L-Series, T-Series, and Thermal Plunge Series.
Speck Swim Jet Systems & Equipment Packs Electrical Inspection Checklist
•
This form must be completed to confirm the unit(s) is installed per the original manufacturer’s
guidelines. Speck equipment is commonly part of the jet systems and circulation systems on the
following pool models: 2000, 1200, 3500, 3500i, 750, 750i, 500, 500i, L-Series, T-Series, and Thermal
Plunge Series.
Typical Plumbing Contractor Scope-of-Work:
Provide all labor, materials and equipment necessary to install interconnecting plumbing between each
HydroWorx pool component and the pool shell as required by the owner’s design documents and in
accordance with this HydroWorx Design & Installation Guide. All HydroWorx equipment (pumps,
filter, motors, etc.) must be kept off of the mechanical pit floor by means of a skid or other blocking.
The pools treadmill motor has its own base that is secured to the concrete slab.
Below you will see a typical picture of a sump pit.
Page 9
Provide means to drain the pool and the maintenance system via gravity through a 2” PVC drain line
into the sump pit as shown in this Design & Installation Guide. 60 GPM draining capacity in the
HydroWorx mechanical space is the acceptable minimum. Refer to the HydroWorx Drain
Detail. This piping MUST be installed to promote 100% drainage of pool water via gravity.
Maintain pipe invert lower than the drain invert.
All piping, fittings, valves, etc. shall be provided and installed by the plumbing contractor. Unless
otherwise noted, all conveyance piping, fittings, valves, etc. shall be schedule 40 PVC (pressure type)
fastened with heavy-bodied pipe glue. Threaded fittings shall be connected using silicon sealant (do
not use Teflon tape or plumbing pipe-thread sealer).
After the electrician has bumped the motors and checked rotation of the treadmill motor, fill the
pool to hydrostatically test plumbing installed. If the pool is left up and running, add shock and other
chemicals to balance and maintain the water chemistry.
Minimum Start-Up & Testing Requirements:
•
•
•
•
•
•
•
•
•
•
Set up the HydroWorx controls system and underwater video systems
Complete the HydroWorx Site Analysis Checklist and return it to the HydroWorx project
management department for review. Customer in-service training cannot be scheduled until
this is completed.
Confirm the sump pump is wired and the mechanical pit lighting is operational
Prior to filling the pool with water, confirm connectivity of all pool components
Bump all motors and check rotation of the treadmill motor
Complete ALL Electrical Components Installation & Maintenance Inspection Checklists and
Warranty Activation Forms
Confirm the sump pump and/or floor drains are installed and in working order
Confirm the plumbing is installed such that the pool drains into the sanitary system as required
Clean and fill the pool
Leak test all plumbing connections and confirm valve configuration
Following completion of the start-up and testing work identified on the HydroWorx Site Analysis
Checklist, a HydroWorx representative will schedule a site visit with the owner to perform training and
place the pool in service.
Page 10
HydroWorx Design & Construction Checklist
This document is designed to provide steps to improve the coordination of the HydroWorx pool(s) in the design
and construction phase of the project.
Step 1
Have you requested HydroWorx AutoCAD files for the specific pool model selected by the owner?
The structural stage is NOT too early because these units have design requirements that significantly impact that
phase of design.
Have you had a conference call with a HydroWorx design & construction representative to discuss design
requirements, scope of work, lessons learned etc.?
This is critical to have as EARLY as possible in the project. It is very useful in understanding the connection
between Architectural, Structural, Mechanical, Electrical, Plumbing and the design & installation requirements of
a HydroWorx pool.
Have you requested and incorporated the HydroWorx CSI specs into the bid document?
Step 2
Have you provided HydroWorx the pool room design for review and comment?
Step 3
Have you provided HydroWorx with project approved final drawings?
Top Lessons Learned:
Page 11
1.
Setback requirements are not adhered to creating access issues for service or component failure due to
incorrect design.
2.
Scope of work is not clearly defined in bid documents resulting in change orders that impacts the owner.
3.
“Verify / Coordinate with pool manufacturer” is a common note on drawings that go to bid and lead to
errors and omissions or change orders that can be avoided by verifying the design requirements.
HydroWorx believes it critical that we be involved early in the design / development phase given the
structural and foundation impacts of our product.
4.
Inadequate air circulation provided to address heat loads of equipment.
5.
Verify code compliance requirements early in the design phase. It is left to the end during occupancy
process creating change orders to become compliant.
6.
Installation of the HydroWorx pool into an existing building – It is important to identify any criteria that
are applicable to existing buildings. If not addressed EARLY in the design process they are often not
documented on building “As-Builts”. The potential problem exists of running into unexpected issues that
affect the pool location planning and clearances and require last minute changes. It is critical that your
engineering drawings identify that all piping, electrical service, structural, mechanical etc. is clear or rerouted in the area proposed for the pool location.
7.
Access for the pool and all components must be considered when sequencing the work on-site. It is the
architect/general contractor’s responsibility to provide and maintain the required access from the point of
delivery to the final product location. This may require wall sections being left open with lintels or headers
being used to maintain access or possibly roof sections being left open. Access plan for the pool and
components must be reviewed with HydroWorx.
8.
Copper or salt water treatment system used with pools. These systems will have a negative reaction with the
stainless steel pool components which will result in voiding the pool warranty for the affected components.
Please consult with HydroWorx on any desired alteration to the standard bromine water quality system.
Page 12
500i-1
JUNE 2014
NONE
MM
DRW
500i-2
JUNE 2014
NONE
MM
DRW
500i-3
JUNE 2014
NONE
MM
DRW
500i-4
JUNE 2014
NONE
MM
DRW
500i-5
JUNE 2014
NONE
MM
DRW
500i-6
JUNE 2014
NONE
MM
DRW
500i-7
JUNE 2014
3/8"= 1'-0"
MM
DRW
500i-8
JUNE 2014
NONE
MM
DRW
500i-9
JUNE 2014
3/8"= 1'-0"
MM
DRW
500i-10
JUNE 2014
NONE
MM
DRW
500i-11
JUNE 2014
NONE
MM
DRW
500i-12
JUNE 2014
NONE
MM
DRW
500i-13
JUNE 2014
NONE
MM
DRW
500i-14
JUNE 2014
NONE
MM
DRW
500i-15
JUNE 2014
NONE
MM
DRW
Ethernet Cable
from Control Panel
All-in-One
Computer
Pendant Control Cable
from Control Panel
Hydroworx
Control Pendant
DVR / Video
Switcher
HydroWorx
DVD
GFI
Receptacle
Hydroworx
Underwater
Video Monitor
GFI
Receptacle
Electrical Surge
Suppression Strip
for component
power cords (BY
CONTRACTOR)
Pool Room
Elevation
See Optional
Video Section
Detail
CABINET (BY
CONTRACTOR)
Mechanical Pit
Dedicated Solely for
HydroWorx Low
Voltage Control
Cables
(By Contractor)
OPTION 1
(MONITOR IN CABINET)
Low Voltage Control
Cables
(Furnished By
HydroWorx / Installed
By Contractor)
Mechanical Pit
Dedicated Solely for
HydroWorx Low
Voltage Control
Cables
(By Contractor)
Mechanical
Pit Elevation
Low Voltage Control
Cables
(Furnished By
HydroWorx / Installed
By Contractor)
VIDEO CABINET SECTION VIEW
500i-16
JUNE 2014
NONE
MM
DRW
All-in-One
Computer
PENDANT CONTROL CABLE
FROM CONTROL PANEL
HYDROWORX
CONTROL PENDANT
HydroWorx
GFCI RECEPTACLE
3" CHASE
TO TOP
OF
COUNTER
DIRECTLY IN FRONT OF POOL
ETHERNET
CABLE FROM
CONTROL
PANEL
Hydroworx
Underwater
Video Monitor
Wall Mounted
DVR/VIDEO
SWITCHER
ELECTRICAL SURGE
SUPPRESSION STRIP
FOR COMPONENT
POWER CORDS (BY
CONTRACTOR)
DVD
GFI RECEPTICAL
MAX 50' RUN TO TV
2" CONDUITS IN WALL
HDMI
VIDEO
CABLE
2" CHASE TO
EACH TV
3" CHASE
FROM PIT
COAXIAL
VIDEO
CAMERA
CABLES
MAX 50' RUN FROM POOL
CONTROL CABINET
LOW VOLTAGE CONTROL
CABLES
(FURNISHED BY
HYDROWORX / INSTALLED
BY CONTRACTOR)
OPTION 2
(WALL MOUNTED MONITORS)
500i-17
JUNE 2014
NONE
MM
DRW