Bulldog Security KlassKeeper KKV024 Instruction manual

Last Revised April 2020
Installation, Operation,
& Maintenance Manual
KlassKeeper Heat Pump
KlassKeeper
Models: KKV024 –KKV048

KlassKeeper –Installation, Operation, and Maintenance Manual 1
© Copyright 2013 CGC Group Inc.
Last Revised April 2020 Installation, Operation, and Maintenance Manual is Subject to Change without Notice.
Table of Contents
INFORMATION...................................................................................................................................3
Handling....................................................................................................................................................3
Storage......................................................................................................................................................3
Weight.......................................................................................................................................................3
Unit Dimensions ........................................................................................................................................4
Refrigerant Charge....................................................................................................................................5
Unit Clearances .........................................................................................................................................5
INSTALLATION ...................................................................................................................................6
Delivery and General Installation Checklist...............................................................................................6
Location.....................................................................................................................................................6
Cabinet Placement .................................................................................................................................... 6
Dry Walling (when required).....................................................................................................................7
Piping ........................................................................................................................................................7
Wiring........................................................................................................................................................ 8
OPERATION .......................................................................................................................................9
Inputs & Outputs.......................................................................................................................................9
Operating Modes ....................................................................................................................................10
Alarms .....................................................................................................................................................11
LCD Display Module ................................................................................................................................13
COMMISSION & STARTUP ................................................................................................................14
System Flushing.......................................................................................................................................14
System Fluid ............................................................................................................................................14
System Water pH ....................................................................................................................................14
Water Flow Rate .....................................................................................................................................14
Water System Freeze Protection.............................................................................................................15
Remove Air from System fluid Loop ........................................................................................................15
Air Balancing...........................................................................................................................................15
Clean Unit Filters.....................................................................................................................................15
Fan Rotation:...........................................................................................................................................15
Start-up: ..................................................................................................................................................15

KlassKeeper –Installation, Operation, and Maintenance Manual 2
© Copyright 2013 CGC Group Inc.
Last Revised April 2020 Installation, Operation, and Maintenance Manual is Subject to Change without Notice.
MAINTENANCE ................................................................................................................................17
Inspect Filters ..........................................................................................................................................17
Check Fan motors annually.....................................................................................................................17
Visual Inspection .....................................................................................................................................17
Amperage Check on compressor and fan motor.....................................................................................17
Safety Control Reset................................................................................................................................18
Drain Pan and Condensate Hose.............................................................................................................18

KlassKeeper –Installation, Operation, and Maintenance Manual 3
© Copyright 2013 CGC Group Inc.
Last Revised April 2020 Installation, Operation, and Maintenance Manual is Subject to Change without Notice.
INFORMATION
Handling
Care must be taken in handling the cabinet, chassis, built in ERV and other accessories to ensure that this
equipment does not sustain any damage.
The protective shipping packaging should be kept on until unit is ready for installation. During
construction, the equipment must be sheltered from contaminants and debris such as drywall dust, wood
chips, or paint as these may damage the fan, or block the cooling / heating coil and diminish unit
performance.
Storage
The unit must, at all times, be stored in an upright position with the compressor section at the bottom
and the fan section oriented up.
Failure to maintain the chassis in an upright position may result in permanent damage to the unit.
Dropping the chassis or exposing it to extreme shock or vibration may also result in permanent damage
to the interior components and piping.
Both the chassis and cabinet should be stored in a non-corrosive environment sheltered from conditions
of extreme temperature or humidity. Subjecting the unit to conditions of this nature may result in
significantly reduced performance, reliability, and operational life.
The unit is intended for interior use only and should be stored indoors at all times to protect it from the
elements and to help eliminate the potential growth of indoor air quality (IAQ) contaminants.
If indoor storage is not possible, the equipment may be stored outdoors during the summer months only,
if the following provisions are met:
1. The equipment must be placed on a dry surface, or raised off the ground in a manner which allows
for air-circulation beneath the unit.
2. A waterproof tarp must be used to cover the equipment in order to provide protection from the
elements.
3. Continuous ventilation to the units must be provided to help prevent moisture accumulation on
the interior and exterior surfaces. Moisture buildup on, or within the unit’s insulation may result
in microbial growth that can lead to odors and serious health-related IAQ problems.
4. The chassis must be stored in their original packaging.
5. The individual units shall not be stacked on top of one another.
6. If the unit was previously in use, ensure that all water in the coil has been blown out and that all
hose connections are plugged during storage.
Weight
Model
KKV024
KKV030
KKV036
KKV042
KKV048
Chassis Weight (lbs)
280
280
280
300
300
Cabinet Weight (lbs)
480
Standard Plenum Weight (lbs)
60

KlassKeeper –Installation, Operation, and Maintenance Manual 4
© Copyright 2013 CGC Group Inc.
Last Revised April 2020 Installation, Operation, and Maintenance Manual is Subject to Change without Notice.
Unit Dimensions

KlassKeeper –Installation, Operation, and Maintenance Manual 5
© Copyright 2013 CGC Group Inc.
Last Revised April 2020 Installation, Operation, and Maintenance Manual is Subject to Change without Notice.
Refrigerant Charge
Model
KKV024
KKV030
KKV036
KKV042
KKV048
R410A Charge (oz.)
40
45
50
60
Consult factory
Unit Clearances
Clearances for the KlassKeeper units shall be provided such that the access panel swinging door opens
and closes without obstruction to allow service access to the filters, the unit disconnect, fans and fan
motors, and unit chassis.
In the event of chassis replacement, the front service entrance must permit straight horizontal removal
of the chassis. The return air path must be unobstructed during operation.

KlassKeeper –Installation, Operation, and Maintenance Manual 6
© Copyright 2013 CGC Group Inc.
Last Revised April 2020 Installation, Operation, and Maintenance Manual is Subject to Change without Notice.
INSTALLATION
The Installation of KlassKeeper units and accessories must be in accordance with all local codes and
regulations of all relevant governing authorities having jurisdiction. The following installation procedures
are recommended by the Manufacturer.
It is the responsibility of the installing contractor to comply with all applicable codes and regulations.
It is the responsibility of the installing contractor to ensure adequate service clearance for regular
maintenance or for repair in place, is exercised. The installing contractor will be responsible for
removing the unit if it is not repairable in place.
Delivery and General Installation Checklist
The information below details the correct installation procedure for a KlassKeeper unit. Please read this
document in its entirety prior to proceeding with unit installation.
Specific site conditions may warrant variations in locations and dimensions.
1. Remove packaging and inspect the unit. Check for shipping damage or material shortage; file a
freight claim and notify your sales representative if damage or deficiency is found.
2. Verify the correct model and voltage as indicated by the model number.
3. Verify the installation location of the unit.
4. Verify that the power supply complies with the nameplate specification.
5. Connect properly sized and protected power supply wiring to the disconnect in the cabinet.
6. Install proper grounding wires to an earth ground on the cabinet as well as the receptacle.
Location
Locate the unit in an indoor area. The indoor air temperature surrounding and being supplied to the unit
must, at all times, be above 45F (7C). Do not locate the unit in areas subject to freezing.
Cabinet Placement
1. Ensure that there is sufficient clearance in front of the unit to allow the swinging access door to
open freely. A minimum of 5 feet shall be left unoccupied in front of the unit at the same width
as the unit.
2. Plenum (when ordered) is factory assembled and shipped loose for field installation by others.
Plenum is mounted on the cabinet’s top.

KlassKeeper –Installation, Operation, and Maintenance Manual 7
© Copyright 2013 CGC Group Inc.
Last Revised April 2020 Installation, Operation, and Maintenance Manual is Subject to Change without Notice.
Dry Walling (when required)
It is permissible to glue or screw drywall directly to the side of the cabinet. Please note that the drywall
screw must not be longer than the drywall thickness plus a maximum 3/8”.
Ensure drywall is not obstructing the swinging access door.
Piping
CAUTION: Piping must comply with all applicable codes and regulations.
1. Run supply, return and condensate pipe inside the cabinet through the top knockouts
2. Install isolation valves to permit unit removal for servicing.
3. DO NOT bend or kink supply lines or hoses (If supplied). Supply and return hoses are fitted with
swivel joint fittings at one end to allow removal for future servicing.

KlassKeeper –Installation, Operation, and Maintenance Manual 8
© Copyright 2013 CGC Group Inc.
Last Revised April 2020 Installation, Operation, and Maintenance Manual is Subject to Change without Notice.
Wiring
1. Connect the wire harnesses
between the chassis, ERV and
cabinet as per the below diagram.
2. Connect the power plug to the
receptacle in the cabinet.
Wire Harness
Type
Harness Length
Harness Pin #
I/O
1
Signal
42”
12
DI 1-5, AN1, AN3, K7
2
Signal
42”
5
K5, K8, spare
3
Signal
18”
9
TH4-TH7
A
Power
42”
4
ERV Power
B
Power
42”
6
Fan(s) Power

KlassKeeper –Installation, Operation, and Maintenance Manual 9
© Copyright 2013 CGC Group Inc.
Last Revised April 2020 Installation, Operation, and Maintenance Manual is Subject to Change without Notice.
OPERATION
Inputs & Outputs
The KlassKeeper can be completely controlled by a BAS without a third party controller or a thermostat.
Modbus RTU is standard. BACnet gateway is optional.
The controller within the KlassKeeper heat pump controls the operation of the unit and has several sets
of inputs and outputs, both digital and analog. Their assignments are outlined below:
Digital Inputs
DI1 = Heat Call
DI2 = Cool Stage 1
DI3 = Cool Stage 2
DI4 = Fan Call
DI5 = ERV Call
DI6 = High Pressure Switch
DI7 = Low Pressure Switch
DI8 = Condensate Detector
Note: Inputs DI1 - DI5 are connected to dry-contacts on the third party controller or thermostat.
Analog Inputs
TH1 = Discharge Air Temperature –“TA”
TH2 = Refrigerant Temperature –“TR”
TH3 = Leaving Water Temperature –“TW”
TH4 = Exhaust Entering Air Temperature on ERV –“EX-EAT”
TH5 = Exhaust Leaving Air Temperature on ERV –“EX-LAT”
TH6 = Fresh Air Entering Temperature on ERV –“FRSH-EAT”
TH7 = Fresh Air Leaving Temperature on ERV –“FRSH-LAT”
TH8 = Mixed Air Temperature (Space Return + Fresh Air Leaving) –“MIX-AT”
Note: All temperatures are measured using 10KΩ Type II thermistors.
Digital Outputs
K1 = Compressor Stage 2
K2 = Compressor Stage 1
K3 = Main Fan - Low Speed
K4 = Main Fan - High speed
K5 = ERV Fan
K6 = Cooling Valve
K7 = General Alarm Contact
K8 = ERV Heat wheel
Note: Outputs K2, and K7 are dry-contacts; K1, K3, K4, K5, K6, and K8 provide 24VAC.
Analog Outputs
AN1 = Alarm Flash Code Status Indicator (0-10VDC)
AN2 = Modulating Heat Valve (0-10VDC).
AN3 = DAT Setpoint Signal (0-10VDC). It scales DAT setpoint setting on screen to 0-10VDC where
0V= 50oF and 10V = 100oF