ThermoPlus Air KACE Series Installation and operating instructions

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WATER COOLED AIR CONDITIONERS
HORIZONTAL & VERTICAL MODELS
R410A
INSTALLATION, OPERATION AND MAINTENANCE
SERIES KACE-009A KACE-012A KACE-015A KACE-018A
KACE-024A KACE-030A KACE-036A KACE-042A
KACE-048A KACE-060A KACE-072A KACE-096A
KACE-120A KACE-144A
Warning
Mechanical Thermostat may affect Electronic
Control card in unit. Connect an electronic
Thermostat to unit.
Each air conditioner has been operated and checked out
prior to shipment. Failure to operate after installation
indicates damage in transit or improper installation.
INSPECTION
Check packaging during unloading. Note transit damage on
all copies of bill of lading. Inspect air conditioners for hidden
shipping damage after packaging is removed. Transit
damage claims must be filed promptly with Freight
Company by purchaser.
HANDLING
Always handle Vertical units upright and Horizontal
units flat on their base. Moving a vertical unit on its side,
placing a horizontal unit on end, or dropping it may damage
internal parts and displace oil from the compressor's
crankcase.
STORAGE
If job site storage is necessary, place the unit in a clean,
warm dry area. Follow instructions under Handling.
LOCATION
Note that units with different capacities may have identical
dimensions. Labels on unit packaging must be carefully
scrutinized and matched to job location. These units are not
approved for outdoor installation and therefore must be
installed inside the space being conditioned.
PLACEMENT
Install air conditioners in a level plane and locate unit
around the service panel to ensure that proper access is
available including that for filter removal.
¨For Vertical Units: Install the air conditioner with a piece of
sound insulating material between unit and floor to avoid
possible transmission of noise into the building structure.
(rubber backed carpeting will suffice for vertical models).
For units installed in closets adjacent to conditioned space,
provide insulated return air ducting with at least one 90o
elbow or provide a sound baffle between the return air grille
and unit filter.
¨Horizontal units are provided with isolation hanger
support. See Fig. 2 for proper installation when the unit is
suspended.
LOCATION OF SUPPLY & RETURN CONNECTIONS
(SEE FIG. 1 & 2)
WIRING
All wiring should conform to the CEC and/or local code
requirements. Power disconnect shall be field provided (by
others). The wiring diagram is located on electrical box
cover on vertical models and on the back of the service
panel on horizontal models. Make certain the line voltage
and the 24 volt control circuit are properly identified and
wired in accordance with the unit wiring diagram.
¨Water cooled air conditioners are classified as direct
(permanently) connected devices by the CEC. Air
conditioners must be properly grounded as per instructions
on the unit wiring diagram.
CONDENSATE DRAINAGE
Vertical Units: Ensure that the plastic drain tube is
connected to the bottom of the coil drain pan at one end
and the other end of the condensate drain tube should
extend through the left post on the front side of the unit, see
Fig. 1. Connect the drain through a trap to the condensate
drain system in conformance to local plumbing codes.
Slope the drain line for proper gravity flow of condensate
away from unit. The top of the trap and further connections
must be below the unit drain connection level.
Horizontal Units: The condensate drain tube should be
connected to the side of the unit, see Fig. 2. Follow the
above instructions (given for the vertical units) for proper
condensate draining.
WATER SUPPLY (UNIT CONNECTED ON OPEN WATER
CIRCUIT)
The source of water for air conditioner operation is the
responsibility of the owner and/or the installing contractor.
The air conditioner must not function without water, and
predetermined rates of flow (l/s or USGPM) must be
maintained for the unit to opera-te at rated capacity. Since
the water function is to absorb heat from the refrigerant, the
flow rate for each model varies with the entering water
temperature (EWT). A pressure-operated water valve is
installed for this reason inside the unit and SAE-13 calibra-

MAN-KACE-A-E-001
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ted at the factory for a condensing pressure of 1400 kPa
"gauge" (205 PSIG.). Piping size to and from unit must
match or exceed the inlet and outlet water connection
sizes on the air conditioner.
WATER CONNECTIONS
If flexible hoses are used to make the water in-out
connections to the unit, certain precautions must be taken
to ensure proper unit operation and avoid hose damage.
¨Never use a hose of a smaller inside diameter than that of
the water connection sizes on the unit.
¨The hoses must be rated to match or exceed
temperatures and pressures which occur during normal
operation of system (temperature between 4oC (40oF) and
43oC (110oF); and pressures up to 1380 kPa (200 PSI).
¨When hoses are connected they must not be subjected to
any stress in tension or by twisting or kinking.
¨Hoses available as an accessory to the unit are provided
with hexagonal surfaces on the fittings as are the water
fittings on units. Use a properly sized wrench on the
hexagonal surface to tighten connections. Never use a
wrench on the hose or sleeve that crimps the fitting into the
hose.
¨Do not over-tighten connections. Turn in the mating
threads by hand or with a wrench until snug, then tighten
with a wrench beyond the point just enough to seal the joint
(for tapered pipe threads this would be an additional 1/2 to
one full turn; for union or flare connections no more than
1/4 of a turn).
¨Before pressurizing the system, closely inspect the hose
and fittings to be sure there are no cuts, abrasions, twists or
kinks. Hoses must not be in contact with any sharp edge
while in use.
¨Hose supplier will not take responsibility for hose leakage,
failure or damage resulting from water leaks.
SUPPLY DUCTING
Flanges around the blower opening are intended for a
flexible supply air duct connection to unit. Be certain
blower wheel turns freely before making the duct
connection. Supply air ductwork must be insulated with 25
or 38 mm thick (1" or 1 1/2") fibreglass, sealed at all joints
and must have an exterior vapour barrier. The air
conditioner's life expectancy and efficient performance are
dependent on adequate air flow. Under no circumstance
should the unit be installed where the total external static
pressure exceed those shown in the Table 1.
TABLE 1
MODEL EXTERNAL STATIC PRESSURE
Pa inch wg
009 75 0.30
012 75 0.30
015 75 0.30
018 75 0.30
024 188 0.75
030 188 0.75
036 188 0.75
042 188 0.75
048 188 0.75
060 188 0.75
072 25 to 275 0.10 to 1.1
096 25 to 275 0.10 to 1.1
120 25 to 275 0.10 to 1.1
144 25 to 275 0.10 to 1.1
WIRING - LINE VOLTAGE
Check mainpower voltage. Refer to unit wiring diagram and
make changes (if required) to permit the unit to operate on
the available supply voltage. Connect power as per the unit
wiring diagram, conforming to the local and national
electrical code requirements.
CONNECTION AND LOCATION OF THERMOSTAT
Wiring the thermostat to the unit should be done as per the
wiring diagram (inside the panel of the electrical box on the
vertical units and on the inside of the service panel for
horizontal units). Thermostat must be absolutely level when
installed and located to best sense the actual room
temperature. Avoid false sensing heat or cold from sunlight,
open doors or window drafts, supply air outlets, fireplaces,
ovens, etc.
HIGH PRESSURE PROTECTION
Your unit is protected against excessive high pres-sure by a
pressure limiting control. If the pressure rises above 560 psi
(2,758 kPa), the pressure switch will shut down the unit.
RESET UNIT
To restart, the unit must be turned "OFF" at the thermostat
or at the main power switch. Then switch to "ON" position;
the unit will start functioning. If not, call a technician to
solve the problem. Repeated resetting on unit without
getting the fault corrected will cause compressor failure.
START UP INSTRUCTIONS
After installation of unit and the ductwork, water and
condensate connections, the wiring in accordance with
preceding instructions, the unit is ready for start-up. Check
all wire connections to the unit and to external control
devices for tightness.
¨Set temperature on the thermostat below room
temperature and start the unit. After operating for five(5)
minutes, air supply should have a minimum temperature
drop of 10-12oC (18-22oF). Use a surface temperature
device or any other device to check the temperature of
supply water and return water. The minimum temperature
rise should be 6oC (10oF).
¨If the above conditions are not met, one or more of the
following problems exist: low air flow, low water flow, or unit
is possibly defective.
MAINTENANCE AND SERVICE
¨Do not operate the air conditioner without the air filter in
place. Filters should be serviced regularly, at least every
three months.
Dirty filters will result in inefficient performance.
¨Check the air coil and fan wheel yearly for cleanliness and
clean if necessary.

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FIGURE 1
LEFT SIDE
RIGHT SIDE
FRONT
BLOWER AND MOTOR
ACCESS PANEL
RETURN AIR
SUPPLY AIR
WATER IN
WATER OUT
CONDENSATE
DRAIN TUBE
LOW VOLTAGE IN
POWER IN
BLOWER
ACCESS PANEL
ELECTRICAL AND
COMPRESSOR ACCESS PANEL
ELECTRICAL
ACCESS PANEL
WATER REGULATING
ACCESS PANEL

MAN-KACE-A-E-001
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FIGURE 2
RETURN AIR
SUPPLY AIR
FRONT
RIGHT SIDE
LEFT SIDE WATER IN
WATER OUT
LOW VOLTAGE IN
POWER IN
ELECTRICAL ACCESS PANEL
ELECTRICAL
AND COMPRESSOR
ACCESS PANEL
WATER REGULATING VALVE ACCESS PANEL
C
Detail C
3/8 WASHER
(BY OTHERS
3/8-16 NUTS (DOUBLE
(BY OTHERS
3/8-16 THREADED ROD
(BY OTHERS
BLOWER AND MOTOR
ACCESS PANEL
CONDENSATE DRAIN
CONNECTION

Owner’s Manual KAC/KHP/KAC-M/KHP-M Series
ThermoPlus Air, Inc. February 2007 1
Data subject to change without notice.
Installation Wiring Control Signals
Remove the display from its box. Refer to the instruc-
tions included. Separate the display into its three pieces.
Thread the end of the cable thorugh the hole in the sub-
base as shown. Using care to maintain level, screw the
sub-base to the wall box here.
Connect the cable to the modular telephone jack on the
back of the display. Screw the display to its sub-base
here.
Snap the front cover over the display.

KAC/KHP/KAC-M/KHP-M Series Owner’s Manual
2ThermoPlus Air, Inc. February 2007
Data subject to change without notice.
Startup Supervisaire®Controller Interface
STARTUP
Prg
Esc
EEsscc
is used to
return to previous
interface levels.
The backlit LCD screen dis-
plays any needed information
on the operation of the system.
Default screen
present value set point
is used to scroll
downward through
screens and to decrease
settings.
Do not press and
at the same time.
is used to scroll
upward through screens
and to increase settings.
Do not press and
at the same time.
is used to
navigate around
the screen and to
accept inputs.
While in the
default
screen, press
the Prg
button to
display the
program
version.
is used to
access the list of
alarm conditions, if
any exist.
HUMIDITY aaa / bbb %
ROOM AIR ccc / ddd F

Owner’s Manual KAC/KHP/KAC-M/KHP-M Series
ThermoPlus Air, Inc. February 2007 3
Data subject to change without notice.
Set Display Address Startup
To set the display address, follow these instructions.
1. If safe to do so, turn on the electric power to the unit.
If the display shows “Humidity” and other information, no further action
is needed. If not, proceed to step 2.
Display address
setting . . . . . . . . . . . : aa
I/O Board address : bb
Default Screen
HUMIDITY aaa / bbb %
ROOM AIR ccc / ddd F
xxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxx
Prg
Esc
2. Simultaneously press and hold the , , and buttons for at least
five seconds. The screen at right will appear, where aa and bb are
numbers.
Display address
setting . . . . . . . . . . . : aa
I/O Board address : bb
3. Press . The cursor will move to aa, as shown.
Display address
setting . . . . . . . . . . . : 0
4. Press until aa equals 0.
blinking cursor
Display address
changed
5. Press . Note that “I/O Board address : bb” disappears. The screen
at right appears briefly, followed by the unit default screen.

KAC/KHP/KAC-M/KHP-M Series Owner’s Manual
4ThermoPlus Air, Inc. February 2007
Data subject to change without notice.
Startup Supervisaire®Controller Interface
PROGRAM: xxxxxxxx
MAIN MENU
SCROLL DOWN
FOR OPTIONS
Default Screen
HUMIDITY aaa / bbb %
ROOM AIR ccc / ddd F
GO TO
AUTO/OFF CONTROLS
GO TO
SENSOR READINGS
GO TO
SET POINTS
GO TO
PURGE SETTINGS
GO TO
OCCUPIED PERIOD
OPTIONS
GO TO
CLOCK SETTINGS
There are many possible status messages. This screen is the
gateway to other screens that display these status messages.
See Operation - Controller Messages.
The unit ships with the major components disabled in software.
This screen is the gateway to other screens used to enable or
disable the major components of the unit. See Startup -
Enable Operation.
There are several sensors throughout the unit. This screen is
the gateway to other screens used to display the readings of
these sensors. See Startup - Read Sensors or Operation -
Read Sensors.
This screen is the gateway to other screens used for setting the
operating set points of the unit. The set points are protected by
a user password. See Startup - Adjust Set points or
Operation - Adjust Set points.
This screen appears only on units with the optional Purge fea-
ture. This screen is the gateway to other screens used to adjust
or trigger Purge mode. See Startup - Pre-Startup Adjustments.
This screen appears only on units with the optional occupation
feature. This screen is the gateway to other screens used to
adjust or define occupied periods. See Startup - Pre-Startup
Adjustments.
This screen appears only on units with the optional occupation
feature. This screen is the gateway to other screens used to set
the internal clock (where used). See Startup - Pre-Startup
Adjustments.
GO TO
SERVICE MENU This screen is the gateway to other screens used for service
monitoring or modification.
This displays the version of the
operating program.
GO TO
STATUS MESSAGES
For a controller interface map, see Operation.
Esc
Esc
Esc
Esc
Esc
Esc
Esc
Esc
Esc
Esc
Esc
Prg

Owner’s Manual KAC/KHP/KAC-M/KHP-M Series
ThermoPlus Air, Inc. February 2007 5
Data subject to change without notice.
Startup Pre-Startup Adjustments Adjust Airflow
Before the unit is operated, the supply duct air flow must be measured and set
by a qualified air-balancing technician. Air flow must be measured with all air
side access doors closed.
Air flow is adjusted by changing the variable sheave on the blower motor shaft. Do not
use other sheaves or change the airflow outside the range given on the unit nameplate,
without the express approval of ThermoPlus.
To run the blower only:
1. Turn on the branch-circuit disconnect switch. Some units may have voltage monitors
that prevent operation in the event the branch circuit has voltage that is too high, too low,
has lost a phase, or has reversed phase rotation. If the green LED
is not lit, confirm that the applied voltage is within ±10% of the nameplate voltage
(NEMA MG-1), that all three phases are present, and that the phase rotation is correct.
2. In the unit electrical enclosure, press START on the blower motor overload (if any).
3. Follow the steps below to start the blower. If prompted for a password on units made before 4/2005, enter
1793. For units made after 4/2005, enter 17 or 1793.
If the blower does not turn the proper direction, a qualified person should disconnect electric power and
interchange any two of the branch circuit wires at the unit input lugs. Torque the connectors as discussed
earlier. Do not move any factory installed wires.
4. When air-flow adjustment is complete, the blower can be stopped by repeating the steps above. If
prompted for a password on units made before 4/2005, enter 1793. For units made after 4/2005, enter 17 or
1793.
If possible and safe, leave the electrical power connected to the unit and leave the blower overload
(if any) ON. This will allow the compressor crankcase heater(s) to function. The crankcase heaters
must be on continuously for at least 10 hours before the compressors are started.
Adjust airflow
Important!
Never run the blower without the filters in
place. Regardless of filters, never run the
blower when construction dust is present.
The resulting heat exchanger damage is not
covered by the warranty.
Important!
Airflow must be set and confirmed
before the refrigeration system is
adjusted.
GO TO
AUTO/OFF CONTROLS BLOWER Off
COMPRESSOR #1 Off
COMPRESSOR #2 Off
TURNING BLOWER
AUTO
ENTER TO CONFIRM
ESC TO CANCEL
Press or to toggle
between AUTOMATIC and OFF.
Then press to confirm.
Press repeatedly to return
to the main menu or default screen.
Press repeatedly to reach screen below.
MAIN MENU
SCROLL DOWN
FOR OPTIONS
Default Screen
HUMIDITY aaa / bbb %
ROOM AIR ccc / ddd F
Optional Do not select
compressor(s).
For a controller
interface map,
see Operation.
Prg
Esc
HUMIDITY aaa / bbb %
ROOM AIR ccc / ddd F
Esc
Esc
Esc
Esc
Esc