Cgc Bulldog innkeeper Instruction manual

Installation

Operation

Maintenance

Manual

Vertical Stack Units

(Universal Cabinet)

InnKeeper/HomeKeeper

Models: IKV 008-018 IEV 008-012

HKV 016-036 HEV 016-036

www.bulldogheatpump.com

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Table of Contents

Information...………………………………...…………………………………….………………..…….….....……............................

Handling...………………………………...…………………………………….…………………….………….......................................

Storage...………………………………...…………………………………….…………………….………….........................................

Model Nomenclature...……………………….………...……………………….....….......................…....……....................

Refrigerant Charge.......................................................................................................................................

Weight/Dimension/Clearance...………………………………...……..…………….………..….........….…………....................

Unit Installation...………………………………...…………………………….....…......…....…............……....….....................

General Installation Checklist……….…………………………......……………….........…...........……....……..……..…….......

Location…………………………………...…………………………………………………….....……………..………………….…..……..…..

Cabinet Placement...………………………………...……………………………...........…….....……..…….…………....................

Riser Bundle Installation (When Ordered).………..…………………………......…….....………..……......……..........…....

Electrical Wiring…..……………………………………..………………..……………………………..…………..…………………….........

Dry walling and Chassis Installation…………………..…………………………………………………..…..………..…..………......

Unit Operation –In Suite………..……….....…………………………………………………………………..……………..………....

Standard Panel and Boot Installation...........................................................................................................

Operation –Detailed……..……………………………….....……………………………………………....……….........……..........

Commission and Start Up………..……….....……………..……………………………………………………………..…..….…......

Maintenance……..………....……….………………………………………………………………………..……................................

Details………..……….....………………………………………………………………………………..………......................................

InnKeeper Universal Cabinet Detail Drawing….…………..............………………………………..…….......……...

HomeKeeper Universal Cabinet Detail Drawing…..……….....…………………………………....……....…………..

Generic Wiring Diagram for IKV008-018 Units………..……….....……………………….……..….……………………

Generic Wiring Diagram for HKV016-036 Units...………………………………...……………….…..……………......

InnKeeper Universal Cabinet Template……….......….....…..………………......………...……...........………..…..

HomeKeeper Universal Cabinet Template………...………...…………….................………....………....………..

Diagnosis Table………..……….....…………………………………………………….....………………….....…..……............

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Information

Handling

Care must be taken in handling the cabinet, chassis, risers, and other accessories to ensure that this

equipment does not sustain any damage. It is recommended that the chassis, and cabinet be transported

individually on a two-wheel cart.

The protective shipping packaging should remain on the chassis, and cabinet until they are ready for

installation. During construction, the unit must not be run and shall be sheltered from contaminants and

debris such as drywall dust, wood chips, and paint that could damage the fan or block the cooling/heating

coil which may result in diminished performance.

Storage

The cabinet should be stored upside down to prevent damaging the foam gaskets on the underside of the

cabinet. The cabinet, risers, and chassis should be stored in a non-corrosive environment sheltered from

conditions of extreme temperature or humidity. Subjecting the unit, and risers to conditions of this nature

may result in significantly reduced performance, reliability, and operational life.

The chassis must be stored in an upright position at all times with the compressor section towards the

ground and the fan section oriented upwards.

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.

Dropping the unit or exposing it to extreme shock or vibration may also result in permanent damage to

the interior components of the unit. 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.

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.

3. The chassis and units must be stored in their original packaging.

4. The individual units shall not be stacked on top of one another.

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.

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Model Nomenclature

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Refrigerant Charge

Unit Model

IKV

008

IKV

010

IKV

012

IKV

015

IKV

018

HKV

016

HKV

020

HKV

024

HKV

030

HKV

036

R410A Charge (oz.)

Weight/Dimension/Clearance

Physical

Details

Physical

Details

InnKeeper

IKV008 |IKV010 |1KV012 |IKV015 |IKV018

HomeKeeper

HKV016 |HKV020 |HKV024 |HKV030 |HKV036

Universal

Cabinet w/

Standard RA

Panel

Dimensions

L x W x H

Weight, lbs.

(kg)

14” x 18” x 84”

(355 x 457 x 2,133mm)

110 (50)

20” x 20.5” x 84”

(508 x 521 x 2,133mm)

135 (61)

Chassis

Dimensions

L x W x H

Weight, lbs.

(kg)

13” x 16” x 48”

(330 x 406 x 1,219mm)

125 (57) |125 (57) |125 (57) | 150 (68) | 150 (68)

18”x 18” x 57”

(457 x 457 x 1,448mm)

180 (82) | 180 (82) | 180 (82) | 180 (82) | 180 (82)

Refer to Detail Drawings on pages 23-24.

Unit Clearance:

The vertical stack product has a sound-dampening front cover panel. The sound-dampening panel slides

off with minimal service clearance, however, 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.

The installation of all vertical stack product and components and accessories must be in accordance with

all local code and regulations of all governing authorities having jurisdiction. The manufacturer

recommends the following installation procedures.

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 serviceable in place.

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Unit Installation

The information below details the correct installation procedure for a universal vertical stack unit.

Please read this document in its entirety prior to proceeding with unit installation.

Specific site conditions may warrant variations in locations and dimensions.

General Installation Checklist

1. Remove packaging and inspect the unit. Carefully

check for shipping damage or material shortage; file

a freight claim and notify appropriate sales

representative if damage is found.

NOTE: The chassis, and front panel are separate

from the cabinet and risers.

2. Verify the correct model and voltage as indicated by

the model number.

3. Verify the installation location of the unit using the

sheet metal template that is provided.

4. Verify that the power supply complies with the

nameplate specification.

5. Connect properly sized and protected power supply

wiring to the electrical receptacle by others in the

cabinet.

6. Install proper grounding wires to an earth ground on

the cabinet as well as the receptacle.

Location

Determine cabinet location using manufacturer supplied

template. Refer to InnKeeper & HomeKeeper Universal

template drawings (Pages 27-28).

1. Locate core holes for risers using supplied template.

2. Locate unit in an indoor area. The ambient

temperature surrounding the unit must not be less

than 45⁰F (7⁰C). Do not locate the unit in areas that

may be subjected to freezing temperatures.

Figure 1

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Cabinet Placement

1. Review riser schedule to identify cabinet type and location.

2. Position the cabinet. Shim to cabinet level, then anchor the cabinet with concrete bolts to floor

(See Figure 2). If installing a base extension, bolt the extension to the concrete floor

(See Figure 3).

3. The riser knockout to be left exposed for riser installation.

Figure 3

Figure 2

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Riser Bundle Installation (When Ordered)

1. The supply and return risers are standard type “M” copper. Type “L”

copper is optional. The condensate riser is a type “M” copper.

2. Risers are factory swaged expanded top end to accept riser from the

unit above to minimize field brazing. The factory will also pre-install

service isolation ball valves on the supply and return risers.

3. The risers are pre-bundled with a metal channel and cabinet with

neoprene isolation to prevent metal-to-metal contact with housing.

4. Match unit location with riser bundle nomenclature as, indicated by

the manufacturer supplied riser schedule, and the label affixed to the

riser bundle.

5. Refer to Figure 6 (pg. 9) for positioning of risers pertaining to floor-to-

floor installment. The riser diameter shall be shown on plans. Riser

length and schedule shall be coordinated with the mechanical

contractor.

6. Hang the rider bundle slip fit connection onto the riser Knockout on

the cabinet, see Figure 4.

7. Align and insert riser into swage top end of the risers below.

Do not scrape or dent the risers during positioning.

8. The risers’ bottom ends should slide approximately 2”

of the 3” swage top ends. This will allow for the floor-to-floor

variations and prevent the riser joints from bottoming out.

9. Expansion allowance is not needed as the

difference between the summer to winter

temperature change is minimal.

10. Braze riser joints with Sil-Fos or 95/5 tin antimony solder. Perform a

system leak test.

11. A fire stop may be required for the riser openings in the floors.

Consult local fire codes for dictation on appropriate requirements.

Figure 4

Figure 5

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Riser Drawing

Figure 6

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Electrical Wiring

Main Wiring

Electrical connections are made to the cabinet. Cabinets have knockouts for a standard single gang

electrical box. Receptacle may be included with unit if ordered. Box must not protrude into cabinet

more than ½” or it will interfere with the chassis installation or removal.

Receptacles required to match factory supplied cord are as follows.

Current (A)

Models

Phase

NEMA

Configuration

Voltage

(V)

Part #

Configuration

IKV008-

IKV018

6-15R

208-230

PWR-0401

HKV016-

HKV024

6-20R

208-230

PWR-0402

25-30

HKV030-

HKV036

L6-30R

208-230

PWR-0404

Note: Ensure that the ground wire is fastened to the cabinet and receptacle.

Control Wiring

The BULLDOG Heat Pump does not have a reversing valve. The compressor is OFF in heating

use. DO NOT use Heat Pump configuration on thermostats. Set thermostat to Gas or ELC.

See Figure 8 for Standard Control wiring of a single stage heat, single stage cool thermostat wiring.

Figure 7

Figure 8

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Dry Walling and Chassis Installation

1. Attach drywall to front of unit to ensure the proper

fit of acoustic panel as shown in Figure 9.

2. Glue or attach drywall with screws to the front of

cabinet.

3. It is permissible to glue or screw drywall directly to

the side of the cabinet as long as the riser bundle is

not on that side. Please note that the drywall screw

must not be longer than the drywall thickness plus a

maximum 3/8”.

4. Use studs to frame in the riser side of the cabinet

where necessary. Keep screws away from the riser

pipes.

5. Mount thermostat and connect to the thermostat

wire. Ensure that the thermostat is not mounted in

direct sunlight, or within the supply airstream of the

heat pump unit.

6. Install chassis.

7. Connect Supply/Return hoses and condensate line

to risers ensuring condensate hose as a trap.

See figure 10.

8. Perform a leak test and ensure that the hose clamp

on the condensate line is tight.

9. Wire thermostat to control board. Connect power

cord at cabinet electrical box.

Figure 9

Figure 10

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Unit Operation – In Suite

CAUTION:

To avoid fouled machinery, extensive unit clean up, and void warranty, do not operate units without

air filters in place, and do not operate units during the construction process.

The BULLDOG Heat Pump provides year round cooling and heating controlled by your in-suite wall

mounted thermostat.

The BULLDOG Heat Pump provides DX cooling with a water-cooled refrigeration circuit, and hydronic

heating with a hot water coil. The compressor operates in the cooling mode only and shuts down during

the heating mode, providing for quieter operation, extended compressor life, and a reduction in energy

consumption.

To ensure correct operation, centralized equipment located within the building mechanical room is

automatically controlled to provide each heat pump unit with water that is at the proper temperature

and flow rate.

Fan Operation:

Each heat pump has two-speed fan operation. The fan operates as follows:

LOW Speed - First stage of heating mode (Thermostat Setting: Fan Automatic)

- Fan only operation (Thermostat Setting: Fan On)

HIGH Speed - The second stage of heating mode

-Cooling mode

Standard Heating Operation:

Each heat pump has two stages of heat operation. The compressor does not operate in either stage.

To enable heating operation, Manual Change Over thermostats (MCO) must be set to “Heat” mode.

Automatic Change Over (ACO) thermostats should be set to “Auto” or heat mode. To start heating

operation, the suite temperature must fall below the heat set-point temperature.

The thermostat will automatically stop heating operation once the space temperature rises up to the

heat set-point temperature.

Stage 1 Heating: Fan operates at low speed for 10 minutes with minimal noise in an attempt to elevate

suite temperature to desired level.

Stage 2 Heating: After 10 minutes, if set-point temperature is not reached, fan will automatically step up

and operate at high speed.

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Cooling Operation:

Each heat pump has a water cooled refrigeration circuit that operates only during the cooling mode.

To enable cooling operation, MCO thermostats must be set to “Cool” mode. The ACO thermostats

should be set to “Auto” or cool mode. In order for the cooling operation to become activated, the suite

temperature must rise above the cool set-point temperature.

The thermostat will automatically stop cooling once the space temperature drops below the cool set-

point temperature.

Cooling: The fan always operates at high speed during the cooling operation.

The compressor also operates during the cooling operation.

Time Delays:

-Thermostat time delay up to 5 minutes upon initial power up.

-Thermostat time delay up to 5 minutes when switching between heat/cool/off modes.

-Heat pump time delay up to 5 minutes upon initial startup.

-Heat pump time delay up to 5 minutes from the end of a cooling operation to the start of the

next cooling operation.

Recommendations:

1. Set the thermostat fan to ON for continuous fan operation while your suite is occupied. This

will help to ensure that the temperature is uniform throughout the suite.

2. In order to provide space conditioning while you are away, keep the thermostat system switch

in the appropriate heat or cool mode. The heat pump will not heat or cool if the thermostat

system switch is set to the “OFF” position.

3. When away for a short duration, set the thermostat as follows:

a. Set fan to AUTO

b. Set thermostat to appropriate heat or cool mode (based on seasonal conditions).

c. Set heat or cool set-point to your desired suite temperature (ie. 72°F or 22°C).

4. When away for an extended period, set the thermostat as follows:

a. Set fan to AUTO

b. Set thermostat to appropriate heat or cool mode (based on seasonal conditions).

c. During cooler seasons set your thermostat to a minimum set point of 65°F (18°C)

d. During warmer seasons set your thermostat to a maximum set point of 78°F (26°C)

5. It is recommended that you maintain the same set points throughout the day regardless if you

are in your suite or not. This provides maximum comfort for occupants. If you must adjust the

set-point during the night or during away periods in the day it is recommended that heating

setback be limited to 2 degrees and cooling to 4 degrees. This will help to ensure the unit

operates minimally; preventing your suite from becoming excessively cold or hot.

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Standard Panel and Boot Installation

1. Locate the two upper and lower clips and fix them to the cabinet.

2. Locate the boot and lock it into place at the base of the unit using the lower clips to secure it.

3. Hang the front panel on upper clips. Lock front panel into top of boot.

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Operation – Detailed

The unit circuit board incorporates six relay outputs with the following uses:

K1 –Auxiliary relay for cooling valve on a two-valve unit or heat valve on a dehumidification

unit.

K2 –Heating Relay

K3 –Alarm Relay

K4 –Compressor Relay

K5 –Low Fan or Fan Relay for belt drive units

K6 –High Fan or Compressor #2 on belt drive units

Each of these relays have in parallel, a green LED indicator that illuminates when the relay is

energized.

The board incorporates digital inputs that are opto-coupled to a 24V AC source. These inputs

have amber LED indicators that will illuminate when an input is present. These inputs include:

High Pressure Switch

Low Pressure Switch

Heat Call (W on thermostat terminal)

Cool Call (Y on thermostat terminal)

Fan Call (G on thermostat terminal)

Auxiliary (A on thermostat terminal)

Compressor shutdown (24V AC signal thru O/O). Providing a continuous 24V potential to O/O

will terminate and prevent compressor operation. This can be used for duty cycling, or for

minimizing power consumption during a power failure, while maintaining the heating function.

Unit shutdown (24V AC signal thru A/O). Providing a continuous 24V AC potential to A/O will

terminate and prevent unit operation. This can be used for a simple night shutdown. On both

arrangements a single 24V AC signal can shutdown many units. ¼ va is required per unit.

The board also has four analog inputs provided via thermistors. These inputs are as follows:

Ta –Discharge Air Temperature

Tr –Refrigerant Temperature

Tw –Outgoing Water (system fluid) Temperature

Co –Condensate Level

Ta, Tr, And Tw are 10k Ohm NTP thermistors, while Co is a 100 Ohm NPT thermistor. These

Inputs do not have LED indicators.

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Fan Operation

1. A call on “G” for fan on the thermostat terminal strip will cause the fan to operate

continuously on low fan speed through K5 on multi speed units.

2. A call on “W” for heat on the thermostat terminal strip will also cause the fan to operate on

low speed. After 10 minutes of a continuous heating call, the multi speed units will be

switched to high speed through Relay K6.

3. A call on “Y” for cooling on the thermostat terminal strip will cause the fan on multi speed

units to step up to high speed through Relay K6.

4. Fan operation will terminate whenever heating or cooling calls are dropped.

5. Both relays and their associated LED’s are energized when the fan is in high speed.

Heat Operation

A call on “W” for heat will turn on the fan at low speed. Simultaneously, it will energize the heat relay K2

and it’s LED. The relay K2 will provide 24V AC fused power directly to the heat valve.

Cool Start Up

1. A call on “Y” for cooling initiates a series of checks prior to the startup of the compressor. These

checks include:

a. Power ON timer –Compressor operation is delayed for approximately 5 minutes after

restoration of power. This prevents all units coming on-line at the same time once

power is restored. It also prevents compressor jolting as a result of intermittent power.

b. Anti-Recycle timer –There is a 5-minute anti-recycle delay timer that allows the

refrigeration cycle to achieve pressure equalization so that the compressor is unloaded

upon start up.

c. High Pressure Switch –The high refrigerant pressure switch must be closed prior to

start. LED 11 will be ON.

d. Low Pressure Switch –The low pressure switch operates primarily as a loss of charge

protector. It must be closed for compressor start up and LED 12 will be ON. The pressure

switch has a 5 minute ignore subsequent to start-up. In some situations, particularly

when the unit is cold, the pressure switch will open during start-up. If the switch does

not remake within the 5 minute ignore period, the compressor will be immediately

stopped.

e. Air Temperature Sensor Ta –Sensor Ta will prevent compressor operation if the air

flowing through the unit is below 40F (4.4C).

f. Water Temperature Sensor Tw –Sensor Tw will prevent compressor operation if the

outgoing system fluid temperature is above 125F (52C).

g. Refrigerant Temperature Sensor Tr –Sensor Tr will prevent compressor operation if the

coil temperature is below 40F (4.4C).

h. Any of the above faults will be indicated with the Diagnostic Code described under

Diagnostics Table –Page 29.

Cool Operation

1. Monitoring of the refrigerant cycle continues during operation of the compressor. The following

malfunctions will cause the compressor to shut down:

a. If the head pressure exceeds the set point of the high pressure switch, it will open, and

the control board will terminate the compressor operation within 10 seconds. At this

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

time the flash code 6 will be initiated on the red diagnostic LED. Compressor operation

will be restored in accordance with the “Intelligent Reset” algorithm.

b. If the suction pressure drops below the set point of the low pressure switch, the switch

will open and if it remains open beyond the 5 minute ignore period after start up,

compressor operation will be terminated within 10 seconds. Compressor operation will

be restored in accordance with the “Intelligent Reset” algorithm. A flash code of 5 on

the red diagnostic LED will be initiated at this time.

c. Intelligent Reset Algorithm –If a low or high pressure switch opens, the compressor will

be shut down. There is a 10 minute delay before the system is automatically reset, after

which if there is a cool call in place and all other enablers are within the start

parameters, the compressor will again be put into operation. Should either of the

pressure switches open again, the shutdown procedure will cycle again, followed by a

restart. The intelligent reset will allow two open switch shutdowns and restarts in a 24

hour period, but a third shutdown within 24 hours will put the refrigeration system into

a full and hard lockout requiring a power down to reset. If two or less switch open

shutdowns occur within a 24 hour period, they will be erased from memory and will not

contribute to a future hard lockout. (A hard lockout will prevent compressor operation

until the controls are powered down for at least 20 seconds, while a soft lockout is a

compressor shutdown that will be restored once the conditions causing the shutdown

have been rectified.

d. During compressor operation, refrigerant temperature, system fluid temperature and

discharge air temperature are continuously monitored. If the refrigerant temperature

drops below 40F, compressor operation will be disabled. After 10 minutes an auto

reset occurs and the compressor will be enabled as soon as the temperature rises above

65F. Actual compressor restart will be delayed a minimum of 5 minutes by the anti-

recycle timer. A flash code of 2 will be initiated upon a low refrigerant temperature

shutdown.

e. During compressor operation, if the condenser leaving temperature rises above 140F,

compressor operation will be disabled. After 10 minutes an auto reset occurs and the

compressor will be enabled as soon as the temperature drops below120F. The

outgoing system fluid sensor is mounted on the leaving fluid pipe. Actual compressor

restart will be delayed a minimum of 5 minutes by the anti-recycle timer. A flash code of

3 will be initiated upon a high outgoing system fluid temperature shutdown.

f. If the discharge air temperature drops below 40F compressor operation will be

disabled. After 10 minutes an auto reset occurs and the compressor will be enabled as

soon as the temperature rises above 55F. The discharge air temperature sensor is

mounted on the fan housing. Actual compressor restart will be delayed a minimum of 5

minutes by the anti-recycle timer. A flash code of 4 will be initiated upon a low

discharge air temperature shutdown.

g. The condensate level sensor is a 100 ohm thermistor that is heated for 15 seconds every

4 minutes. Its temperature is measured at the beginning of the heat cycle, and again at

the end of the heating cycle. If the condensate level rises above the sensor it will not

warm up during the warm up cycle, and the temperature change will be insignificant. It

is this lack of temperature change that the controller sees as an impending condensate

overflow. When high condensate level is detected, compressor operation is immediately

terminated, and at the same time the fan is stopped for 30 seconds, and then restarted.

At this time a flash code of 7 will be initiated. The 4 minute cycle will continue until the

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

cooling call is no longer in place. If the condensate level drops below the sensor,

compressor operation will be returned to normal. However, if the condensate level

stays above the sensor for more than 15 minutes, the fault alarm will be triggered. This

fault signal will automatically reset once the condensate level goes below the sensor.

Note: The last flash code will be maintained in memory for 1 week or until the unit controls are powered

down. The flash code will continue until the problem has cleared and the compressor has been put into

operation. If a cooling call is in place, it must be disengaged before the cause of the last alarm shutdown

can be identified.

Operation Algorithm Style

There are several control algorithms to prevent cycling and problematic operation. These are:

1. Double Call –If thermostat connections or set up is incorrect resulting in a simultaneous call for

both heating and cooling, the unit will not operate. This condition can be observed on the

thermostat connection LEDs. (Note: A heat pump thermostat will present this scenario)

2. Reverse Cycle Call –Poorly located automatic changeover thermostats (ie. thermostats mounted

on a wall opposite a discharge grill, or a thermostat in a doorway to outside) can trigger heating

and cooling mode changes many times an hour. The CGC controller has a 10-minute anti-mode

change timer for both heating and cooling mode changes. The controller will not accept a

change in mode until 10 minutes have elapsed since termination of the opposite call.

Thermostat Connections Style

The BULLDOG control board has been designed to operate with most standard 24V AC thermostats. These

are powered from the CGC board with 24V AC and simply switch power ON to each of the Heat (W), Cool

(Y), Fan (G) or Aux (A). While most present day thermostats operate in this manner there are others that

may or may not work properly. The following should be checked out for satisfactory performance prior to

installation:

1. Heat Pump Thermostat –Some heat pump units do not have heat relays (therefore are not

compatible with standard thermostats) and require “Heat Pump Thermostats”. These

thermostats call for both heating and cooling on one of the signal wires. These thermostats are

completely incompatible with BULLDOG’s controller.

2. Battery powered thermostats –These thermostats were developed as replacements for old

mercury bulb thermostats that had 4 wire connections while 24V electronic thermostats

required 5 wires. These will work with a CGC board, although CGC does not recommend them.

They require periodic battery replacement, which is something that should be avoided if

possible.

3. Power stealing thermostats –This type of thermostat is electronic and was also developed as a

replacement for old mercury bulb thermostats. These too are problematic in that they bleed a

small amount of current down the signal wires and this may be interpreted as a signal for heat

or cool.

4. Triac switched controllers –This is a commonly used switching device and all controllers tested

to date have functioned flawlessly. CGC recommends that prior to installation of a third party

supplied controller, it be checked for compatibility. CGC can confirm this.

5. Relay switched controllers –This type of controller works well with CGC devices.

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Shutdown Output

The BULLDOG board has an optional input terminal strip that allows for two types of remote shutdown.

These are a) compressor shutdown and b) unit shutdown.

The advantage of these inputs is that many units can be connected in parallel and when powered by an

independent 24V AC signal one or both of these actions can be implemented. Common uses are:

a. Duty cycling for demand control

b. Global night setback

c. Heating only mode during emergency power periods

The BULLDOG controller is also set up so these shutdown functions can be initiated individually with on

board 24V power. This capability allows unit or compressor shutdown based on a door switch, a light

switch, or occupancy switch. A separate 24V power supply is required if two or more units are being shut

down.

Fault Alarm Output

The BULLDOG board is provided with a fault alarm indication and output. The fault alarm relay provides

normally open and normally closed contacts for use in transmitting fault conditions. NOTE: The fault

alarm is energized for NORMAL, and de-energized for fault. As such, if the unit is not powered, if the

board fuse is blown, or if the electronics are damaged, a fault condition will be indicated.

The fault relay is paralleled with the Fault LED which will be ON when no fault condition exists.

Other fault conditions are:

a. Hard lockout due to high or low pressure switch being open for 10 minutes or longer.

b. Hard lockout due to three high or low pressure shutdowns in a 24 hour period.

c. High level condensate for a period in excess of 15 minutes.

Commission & Start Up

System Flushing:

Proper system cleaning and flushing is an important aspect of the commissioning and startup procedure

for the units. Ensure the system has been flushed properly. This prevents fouling of the unit’s heat

exchangers. It is common for debris to settle out in areas of the system where there is low flow or low

fluid velocity. This causes nuisance alarms as a result of a fouling heat pump. It is necessary to flush these

units out as they appear to contain debris build up. This is the responsibility of the contractor and not a

heat pump defect.

NOTE: Hydronic coils are not 100% drainable.

System Fluid:

Ensure that system water temperature is within an acceptable range to facilitate start-up (80-120°F) for

cooling and (100 –140°F) for heating.

System Water pH:

System water should have a neutral pH balance of approximately 7.5 which will extend the life of the

hoses, heat exchangers, and other water side accessories.

Vertical Stack Units (Universal Cabinet) –Installation Operational Manual

Water Flow Rate:

Open all isolation valves to the unit. Ensure that the entering and leaving fluid temperatures of the unit

in operation are acceptable. There is typically an 8 to 12 degree drop or rise in temperature, depending

on whether the unit is in cooling or heating. Under extreme conditions, slight variances in the temperature

may be noted.

Freeze Protection from Water System:

Ensure that freeze protection is provided for the outdoor portion of the loop water system. Inadequate

freeze protection can lead to coil damage.

NOTE: A potential issue may arise during construction where the system fluid loop is drained after being

cleaned, flushed and tested. BULLDOG vertical stack units will not completely drain and may hold fluid in

the condenser or heating coil. Extensive damage may result to internal components if the system fluid

freezes unless adequate glycol is added.

Remove Air from System Fluid Loop:

Air in the system impairs unit operation and can cause erosion in the system piping.

Air Balancing:

Air balancing of the system should be performed while the unit’s fan is operating at high-speed. In order

to ensure the fan is operating at high-speed, the unit must be placed into cool mode.

Clean Unit Filters:

Confirm that the unit filters that are being used are clean. This contributes to the proper operation of the

unit by ensuring that there is adequate air flow across the coil.

SAFETY NOTE: In the following part of the procedure it will be necessary to access the areas around the

electrical wiring and the circuit board. Do not adjust or remove any board connections or wiring

connections to other components without first powering down the unit. Disconnects are usually within

reach of the unit. Exercise caution at all times.

Fan Rotation:

Inspect the fan section to ensure that it is free and clear of any debris and that the fan rotates freely.

NOTE: This equipment is designed for indoor installation ONLY.

Start-up

To register the unit warranty proper start-up is required by a factory approved technician. The following

items must be recorded and returned to the factory to register the warranty. The factory reserves the

right to refuse warranty if these details are not provided.

This manual suits for next models

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