HydroWorx International, Inc.

HydroWorx is a registered trademark of HydroWorx International, Inc. Patents Pending

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1420 Stoneridge Drive, Suite CMiddletown, Pennsylvania 17057

Toll: 800-753-9633Phone: 717-902-1923

Fax: 717-902-1933

April 2015

500i Series Design &

Installation Guide

REV 1.8

4-28-15

ContactInformation

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

Page 1

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 2

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 3

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 4

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.

#2 #1

Page 5

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.

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.

#3 #4

#5 #6

Page 6

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 7

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 8

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, L-

Series, T-Series.

Coates Heaters Installation & Maintenance Inspections Checklist

TREADMILL

BONDING

Page 9

• 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 10

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 11

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 12

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 re-

routed 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.

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GFIReceptacle

Low Voltage ControlCables(Furnished ByHydroWorx / InstalledBy Contractor)

3" Ø Opening FromMechanical PitDedicated Solely forHydroWorx LowVoltage ControlCables(By Contractor)

Pool RoomElevation

MechanicalPit Elevation

VIDEO CABINET SECTION VIEW

DVD

HydroWorx

DVR / VideoSwitcher

HydroworxControl Pendant

GFIReceptacle

Electrical SurgeSuppression Stripfor componentpower cords (BYCONTRACTOR)

Ethernet Cablefrom Control Panel

Pendant Control Cablefrom Control Panel

CABINET (BYCONTRACTOR)

HydroworxUnderwaterVideo Monitor

3" Ø Opening FromMechanical PitDedicated Solely forHydroWorx LowVoltage ControlCables(By Contractor)

Low Voltage ControlCables(Furnished ByHydroWorx / InstalledBy Contractor)

See OptionalVideo SectionDetail

OPTION 1(MONITOR IN CABINET)

All-in-OneComputer

NONE

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DVD

DVR/VIDEOSWITCHER

HYDROWORXCONTROL PENDANT

GFI RECEPTICAL

ELECTRICAL SURGESUPPRESSION STRIPFOR COMPONENTPOWER CORDS (BYCONTRACTOR)

ETHERNETCABLE FROMCONTROLPANEL

PENDANT CONTROL CABLEFROM CONTROL PANEL

HydroworxUnderwaterVideo MonitorWall Mounted

3" CHASEFROM PIT LOW VOLTAGE CONTROL

CABLES(FURNISHED BYHYDROWORX / INSTALLEDBY CONTRACTOR)

MAX 50' RUN TO TV MAX 50' RUN FROM POOLCONTROL CABINET

2" CHASE TOEACH TV

2" CONDUITS IN WALL

OPTION 2(WALL MOUNTED MONITORS)

DIRECTLY IN FRONT OF POOL

3" CHASETO TOPOFCOUNTER

GFCI RECEPTACLE

HydroWorx

All-in-OneComputer

COAXIALVIDEOCAMERACABLES

HDMIVIDEOCABLE

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