AAON Controller User Manual

FACTORY CONTROLS SYSTEM
HB Mini - Controller
Technical Guide
Table Of Contents
Controller Overview ........................................................................................................................ 3
General ...................................................................................................................................................................................... 3
Inputs ......................................................................................................................................................................................... 3
Outputs ...................................................................................................................................................................................... 3
Controller Sequence Of Operation ................................................................................................. 4
Fan Mode ...................................................................................................................................................................................
Heating Mode ............................................................................................................................................................................
Cooling Mode ............................................................................................................................................................................
Lockout Modes .........................................................................................................................................................................
4
4
4
4
Controller Installation & Wiring ...................................................................................................... 5
Controller Mounting ................................................................................................................................................................. 5
Important Wiring Considerations ............................................................................................................................................ 5
Programming With The HB Service Tool ...................................................................................... 11
Entering Passcodes ................................................................................................................................................................ 11
General Procedures ................................................................................................................................................................ 11
Module Selection Screens .................................................................................................................................................. 11
HB Mini Controller Status & Setpoints ................................................................................................................................. 12
Main Status Screens .......................................................................................................................................................... 12
Fan Module Status Screens .............................................................................................................................................. 13
Cooling Module Status Screens ........................................................................................................................................ 13
Cooling Module Setpoint Screens ..................................................................................................................................... 14
Heating Module Status Screens ........................................................................................................................................ 15
Heating Module Setpoint Screens ..................................................................................................................................... 16
Alarm Module Status Screens ........................................................................................................................................... 16
HVAC Test Module Screens .............................................................................................................................................. 17
Troubleshooting ............................................................................................................................ 19
Using LEDs To Verify Operation ............................................................................................................................................ 19
HB Mini Controller Fault Condition Operation ................................................................................................................... 19
Appendix ........................................................................................................................................ 20
Notes: ............................................................................................................................................ 22
WattMaster Controls Inc.
8500 NW River Park Drive · Parkville , MO 64152
Toll Free Phone: 866-918-1100
PH: (816) 505-1100 · FAX: (816) 505-1101 · E-mail: [email protected]
Visit our web site at www.wattmaster.com
Form: AA-HBM-TGD-01A Copyright 2005 WattMaster Controls, Inc.
AAON® is a registered trademark of AAON, Inc., Tulsa, OK.
WattMaster Controls, Inc. assumes no responsibility for errors, or omissions.
This document is subject to change without notice.
Technical Guide
Controller Overview
General
Outputs
The HB Mini Controller is designed to work with a normal 24 VAC
Thermostat. Single or Multi-stage Thermostats can be used. When a
Single Stage Thermostat is used, an auto-staging feature is built-in for
Multi-stage HB units.
Supply Fan High Speed Relay
Supply Fan Low Speed Relay
Cool-1 Relay
Cool-2 Relay
Heat-1 Relay
Heat-2 Relay
Heat-3 Relay
C1, C2: Clogged Filter Switch 24 VAC Output Terminals
The HB Mini Controller also monitors equipment safeties, logs information and locks out the equipment in the event of multiple failures.
Terminal block style connections are provided for field wiring of the
Thermostat. All other inputs and outputs are connected via a wiring
harness on the HB unit. A list of all available inputs and outputs follows.
Inputs
G, Y1, Y2, W1, W2, W3
Outdoor Air Temperature Sensor
Heat Safety Monitor (monitors main and auxiliary limit thermostats)
High Pressure Switch
Low Pressure Switch
Clogged Filter Switch
Figure 1: HB Mini Controller Dimensions
HB Mini Controller
3
Technical Guide
Controller Sequence Of Operation
Fan Mode
The HB Mini Controller controls the 2 Speed Supply Fan . On a call for
"G" the Supply Fan runs at Low Speed. Minimum on and off times are
maintained in the event of a short cycled call for "G".
Heating Mode
On a call for "W1" the Supply Fan runs at High Speed (maintained
during the Heating mode) and Heat Stage 1 is energized. On a call for
"W2", Heat Stage 2 is energized after the stage up delay. If "W2" is
called without "W1", Heat Stage 1 is energized and then Heat Stage 2 is
energized after the Auto Stage Up Delay period. On a call for "W3",
Heat stage 3 is energized after the Stage Up delay. If "W3" is called
without "W1" or "W2", Heat Stages 1, 2 and 3 will energize based on
Auto Stage Up Delays.
Cooling Mode
Speed and Cool Stage 2 is energized after the Stage Up Delay. If "Y2"
is called without "Y1", Cool stage 1 is energized and then Cool stage 2
is energized after the Auto Stage Up Delay.
Lockout Modes
Heating Mode is locked out if the HSM (Heat Safety Monitor) trips 3
times during a call for Heating. To reset the lockout condition, either
remove the call for Heating or cycle power to the HB Mini Controller.
Heating Mode is also locked out if the Outdoor Air Temperature is above
the OAT Heat Lockout setpoint temperature.
Cooling Mode is locked out if the LPS (Low Pressure Switch) trips 3
times during a call for Cooling. To reset the lockout condition, either
remove the call for Cooling, or cycle power to the HB Mini Controller.
Cooling Mode is also locked out if the Outdoor Air Temperature is
below the OAT Cool Lockout setpoint temperature or if the OAT Sensor is bad or missing.
If the HB Mini Controller is configured for 1 stage of Cooling, on a call
for "Y1" the Supply Fan runs at High speed and Cool Stage 1 will
energize. If the HB Mini Controller is configured for 2 stages of Cooling, on a call for "Y1" the Supply Fan runs at Low Speed and Cool
Stage 1 is energized. On a call for "Y2" the Supply Fan runs at High
4
HB Mini Controller
Technical Guide
Controller Installation & Wiring
Controller Mounting
2.
It is important to mount the controller in a location that is free from
extreme high or low temperatures, moisture, dust and dirt. Be careful
not to damage the electronic components when mounting the controller. The HB Mini Controller mounts in the HB unit control panel using
the 4 plastic standoffs located on the HB control enclosure mounting
base.
All wiring is to be in accordance with local and national
electrical codes and specifications.
Minimum wire size for 24 VAC thermostat wiring should
be 22 gauge.
Minimum wire size for all sensors should be 24 gauge.
Be sure that all wiring connections are properly inserted
and tightened into the terminal blocks. Do not allow wire
strands to stick out and touch adjoining terminals which
could potentially cause a short circuit.
Be sure all modular wiring harness connectors are seated
firmly in their respective modular connectors on the HB
Mini circuit board.
3.
4.
5.
Important Wiring Considerations
6.
Please carefully read and apply the following information when wiring
the HB Mini Controller.
1. All 24 VAC wiring must be connected so that all ground
wires remain common. Failure to follow this procedure
can result in damage to the controller and connected
devices.
PIN11 - 24 VAC
ECONO SECTION
PIN12 - RAB
PIN13 - CO2
PIN14 - GND
PIN10 - COM_23
PIN9 - ECONO POS
PIN11 - COM_23
PIN2 - GND
PIN6 - GND
PIN5 - OAT
PIN9 - HT_MON
PIN8 - HEAT_3
PIN12 - GND
PIN7 - HEAT_2
PIN1 - HEAT_1
P9
PIN1 - SW_24VAC
HEAT SECTION
PIN6 - COM_1
PIN8 - CFS
P1
PIN7 - 24 VAC
PIN10 - GND
PIN5 - HEAT_1
PIN2 - 24 VAC
PIN4 - GND
PIN3 - 24 VAC
PIN3 - SPARE IN
PIN4 - 24 VAC
HEAT SECTION
ECONO SECTION
P3
P9
V3
V1
P1
HIGH SPEED
SERIAL
COMMUNICATIONS
CONNECTOR
P3
HSS
K4
LD3
SERIAL #
C20
C38
R30
R58
R61
C46
P-BUS
DRV
C40
R42
R44
D11
R49
R52
C22
R54
R55
D14
R59
X1
R4
C23
R51
R53
D13
C24
R75
R72
R73
R74
P-BUS
P-BUS
R60
C28
R62
R64
D15
C30
C27
U4
R41
VR1
R43
C18
C39
R32
R36
D9
C14
R45
R47
D12
C25
U6
C13
C17
R37
R38
D10
C19
U1
P6
MADE IN THE USA
R35
C15
RN1
HSS
DRV
LD2
R24
R26
R28
D8
R
C
G
Y1
Y2
W1
W2
W3
C1
C2
Q7
LD1
HB MINI
YS102032
REV 1
C41
R63
R65
D16
P11
Q3
Q2
Q5
Q4
PERIPHERAL BUS
CONNECTOR
D3
D2
D17
D4
K5
D22
L1
TB3
HIGH SPEED
SERIAL
COMMUNICATIONS
CONNECTOR
C5
R1
R2
R3
D5
C12
(GND)
R8
R11
R13
C37
U5
C1
See Thermostat
Wiring Diagrams
For Complete Wiring
Connection Details
D19
Q9
D20
R12
R10
R71
R27
R34
R40
D21
Q8
SW1
P8
K2
C3
(R) FROM THERMOSTAT
(C) FROM THERMOSTAT
(G) FROM THERMOSTAT
(Y1) FROM THERMOSTAT
(Y2) FROM THERMOSTAT
(W1) FROM THERMOSTAT
(W2) FROM THERMOSTAT
(W3) FROM THERMOSTAT
(C1) CLOGGED FILTER SWITCH 24 VAC OUTPUT
(C2) CLOGGED FILTER SWITCH 24 VAC OUTPUT
HSS
HSS
HSS
P8
P11
C29
V10
R66
R67
C32
C31
D23
V8
V7
VR2
P4
GND
24VAC
GND
24VAC
PIN2 - 24 VAC
V9
V5
R68
R69
P10
C33
COOLING SECTION
PIN1 - GND
P10
PIN9 - LPS
PIN10 - HPS
PIN8 - COOL_1
PIN11 - LO_SPD
P4
PIN12 - FAN
PIN7 - COOL_2
PIN6 - COND
PIN1 - GND
PIN5 - GND
PIN2 - VFD
PIN4 - LL_TMP
PIN3 - GND
COOLING SECTION
Figure 2: HB Mini Controller Wiring
HB Mini Controller
5
Technical Guide
Controller Installation & Wiring
Single Stage T-stat Wiring For HB Units
Unit
With 1 Stage Cooling & 1 Stage Heating
Single-Stage Thermostat (24VAC)
1-Cool / 1-Heat
W1
Y1
G
C
RC RH
HB Mini Controller Terminal Block
R
(GND)
C
G
Y1
Y2
W1
W2
W3
Clogged Filter Indicator
(Outputs 24VAC)
24VAC
C1
GND
C2
TB3
V10
R69
GND
24VAC
P10
Figure 3: Single Stage T-stat Wiring For HB Unit With 1 Stage Cooling & 1 Stage Heating
6
HB Mini Controller
Technical Guide
Single Stage T-stat Wiring For HB Units
Unit
With 2
1 Stage Cooling & 2
1 Stage Heating
Single-Stage Thermostat (24VAC)
1-Cool / 1-Heat
W1
Y1
G
C
RC RH
HB Mini Controller Terminal Block
R
(GND)
C
G
Y1
Y2
W1
W2
W3
24VAC
Clogged Filter Indicator
(Outputs 24VAC)
GND
C1
C2
TB3
V10
R69
GND
24VAC
P10
Figure 4: Single Stage T-stat Wiring For HB Units With 2 Stage Cooling & 2 Stage Heating
HB Mini Controller
7
Technical Guide
Controller Installation & Wiring
Single Stage T-stat Wiring For HB Units
Unit
With 2
1 Stage Cooling & 3
1 Stage Heating
Single-Stage Thermostat (24VAC)
1-Cool / 1-Heat
W1
Y1
G
C
RC RH
HB Mini Controller Terminal Block
R
(GND)
C
G
Y1
Y2
W1
W2
W3
Clogged Filter Indicator
(Outputs 24VAC)
24VAC
C1
GND
C2
TB3
V10
R69
GND
24VAC
P10
Figure 5: Single Stage T-stat Wiring For HB Units With 2 Stage Cooling & 3 Stage Heating
8
HB Mini Controller
Technical Guide
Multi-Stage
Single
StageT-stat
T-statWiring
WiringFor
ForHB
HBUnits
Unit
With 2
1 Stage Cooling & 2
1 Stage Heating
Multi-Stage Thermostat (24VAC)
2-Cool / 2-Heat
W2 W1
Y2
Y1
G
C
RC RH
HB Mini Controller Terminal Block
R
(GND)
C
G
Y1
Y2
W1
W2
W3
Clogged Filter Indicator
(Outputs 24VAC)
24VAC
C1
GND
C2
TB3
V10
R69
GND
24VAC
P10
Figure 6: Multi Stage T-stat Wiring For HB Units With 2 Stage Cooling & 2 Stage Heating
HB Mini Controller
9
Technical Guide
Controller Installation & Wiring
Multi-Stage
Single
StageT-stat
T-statWiring
WiringFor
ForHB
HBUnits
Unit
With 2
1 Stage Cooling & 3
1 Stage Heating
Multi-Stage Thermostat (24VAC)
2-Cool / 3-Heat
W3 W2 W1
Y2
Y1
G
C
RC RH
HB Mini Controller Terminal Block
R
(GND)
C
G
Y1
Y2
W1
W2
W3
Clogged Filter Indicator
(Outputs 24VAC)
24VAC
C1
GND
C2
TB3
V10
R69
GND
24VAC
P10
Figure 7: Multi Stage T-stat Wiring For HB Units With 2 Stage Cooling & 3 Stage Heating
10
HB Mini Controller
Technical Guide
Programming With The HB Service Tool
Entering Passcodes
The HB Service Tool is used to program setpoints and view the status
of the HB Mini Controller. It is connected to the HB Mini Controller by
means of a modular cable. The cable is connected between the HB
Service Tool and the HB Mini Controller board. The HB Service Tool
doesn’t require batteries or a separate power source as all power to
operate the HB Service Tool is provided through this cable. The HB
Mini Controller must be powered in order for the HB Service Tool to
function.
The passcode entry screen uses a four digit alpha passcode. Position the
cursor under the first letter field. To select the desired letter, use the
ADJUST ARROWS. The UP arrow increases through the alphabet and
the DOWN arrow decreases. When the desired letter appears, press the
RIGHT ARROW key to advance to the next letter field. Once all four
letter fields spell the desired passcode, press the ENTER key.
Available passcodes are:
„
„
Device Address
064
“OPER” = The Operator is at level 1 for Status and
Setpoints
“CONT” = The Contractor is at level 2 for Status, Setpoints
and Force Modes
Again, if no passcode is entered, the default level is 0 and only allows
viewing of the status screens.
General Procedures
When the HB Service Tool is initially powered up, this screen will be
displayed. Press ENTER to proceed to the next screen.
Version: X.XX
Date: XX/XX/XX
When the HB Service Tool is initially powered up, the program version
and the current time and date will be displayed. After the initial power
up, this screen only appears when the HB power is removed and then
reapplied. Press ENTER and the HB Service Tool will check all current
parameters. When it has finished this checking procedure, press ENTER and the main HB programming screen will be displayed. If you
want to change setpoints you will need to enter a passcode at this time.
If you only want to view status, a passcode is not required and you can
proceed to view status directly by pressing the ENTER key.
If you want to change the Passcode, hold down on the UP and DOWN
SELECT ARROWS simultaneously and the following screen will be
displayed.
Enter your passcode as described in the previous section and proceed
by pressing the MENU key. The following screen will be displayed.
Device Address:
064
Line #2 displays the default address for the HB Mini Controller. Press
the ENTER key. The following screen will be displayed.
Device Name
HBMini
Line #2 displays the controller name or program name. Press the ENTER key to advance.
Enter Code
AAAA
Module Selection Screens
After pressing ENTER in the previous step, the first available programming module screen appears. All of the HB Mini Controller Status and
Setpoint Screens are grouped in specific modules designated by a specific function name.
Main Status
Fan Status
Using the select arrows, scroll to select the desired module on line #1
and press the ENTER key. The other available module screens are listed
below in order that they would appear as you scroll down.
HB Mini Controller
11
Technical Guide
Programming With The HB Service Tool
OAT Cool Lockout
Cooling Module
Heating Module
Alarms
HVAC Test
OAT Cool Lockout
NO
Line #2 displays “YES” if the Outdoor Air Temperature is below the
Cooling Lockout Temperature Setpoint.
OAT Temperature
OAT
Factory Options
Factory Options should not be accessed without contacting AAON® or
WattMaster.
XXX F
Line #2 displays the current Outdoor Air Temperature.
Alarms
Warning: The Factory Options settings should only be accessed
when authorized by AAON® or WattMaster Technical
Support personnel. Serious damage to the controller
and/or HVAC unit could result from improper use of
these settings.
HB Mini Controller Status & Setpoints
The Status and Setpoint screens for the various modules are accessed
by selecting a specific module and pressing the ENTER key.
Alarms
NO
Line #2 displays “YES” if an alarm is active. To identify the active
alarm(s), press the ESC key, select the Alarm Module and scroll through
the available alarms using the up and down SELECT arrow keys.
Program Date
Program Date
XX/XX/XX
Main Status Screens
The Main Status Screen is accessed by selecting the Main Status Module and pressing the ENTER key. This screen, as its name indicates,
allows the user to view the Main Status screens for the HB Mini Controller. After the ENTER key is pressed, the following screen will be
displayed.
Line #2 displays the Month/Day/Year that the HB Mini Controller
software was created.
Program Time
HVAC Mode
Program Time
XX:XX:XX
HVAC Mode
Idle
Line #2 displays one of the following HVAC Modes:
•
Idle
•
Venting
•
Cooling
•
Fault
•
Heating
Press the down SELECT arrow key or up SELECT arrow key to move
forward or backward through the Main Status screens as desired.
Line #2 displays the time, in 24-hour (military) format that the HB
Mini Controller software was created .
Program Version
Program Version
X.XX
Line #2 displays the HB Mini Controller software version number.
.
OAT Heat Lockout
OAT Heat Lockout
NO
Line #2 displays “YES” if the Outdoor Air Temperature is above the
Heating Lockout Temperature Setpoint.
12
HB Mini Controller
Technical Guide
Reset Counts
Cooling Stage 1 Energized
Reset Count
XXXX
Y1-Active
NO
Line #2 displays the total number of times the HB Mini Controller has
been reset or has had its power cycled.
Line #2 displays “YES” if there is a 24 VAC signal on HB Mini Controller terminal “Y1”.
Fan Module Status Screens
Cooling Stage 2 Energized
The Fan Module Status Screens are accessed by navigating to the Fan
Module and pressing the ENTER key.
Y2-Active
NO
Fan Terminal Active
G-Active
NO
Line #2 displays “YES” if there is a 24 VAC signal on HB Mini Controller terminal “Y2”.
Fan Status
Line #2 displays “YES” if there is a 24 VAC signal connected to the
“G” Fan terminal on the HB Mini Controller.
Fan Status
Fan Off
High Speed Fan Relay
High Fan Relay
OFF
Line #2 displays the current Supply Fan Status. If the Supply Fan is
on, line #2 displays either “Fan Low Speed” or “Fan High Speed”.
Cooling Relay #1
Line #2 displays “ON” if the High Speed Fan Relay is active.
Cool 1 Relay
OFF
Low Speed Fan Relay
Low Fan Relay
OFF
Line #2 displays “ON” if the Low Speed Fan Relay is active.
Cooling Module Status Screens
The Cooling Module Status Screens are accessed by navigating to the
Cooling Module screen and pressing the ENTER key. The following
screen will then appear.
Line #2 displays “ON” if Cooling Relay #1 is active.
Cooling Relay #2
Cool 2 Relay
OFF
Line #2 displays “ON” if Cooling Relay #2 is active.
Status
Setpoints
Select “Status” by pressing the ENTER key. Press the up or down SELECT arrow key to move forward or backward through the Cooling
Module Status screens.
HB Mini Controller
Low Pressure Switch
LPS
OPEN
Line #2 displays the current status of the Low Pressure Switch. It will
only display “CLOSED” when Cooling Relay #1 relay is active and
the Low Pressure Switch is operating correctly.
13
Technical Guide
Programming With The HB Service Tool
High Pressure Switch
HPS
OPEN
Cooling Minimum On Time
Cool Min On
XXX Sec
Line #2 displays the current status of the High Pressure Switch. It
will only display “CLOSED” when Cooling Relay #1 relay is active
and the High Pressure Switch is operating correctly.
Adjust the desired Cooling Minimum On Time and then press the ENTER key.
Cooling Module Setpoint Screens
Cooling Stage Up Delay
The Cooling Module Setpoints Screens are accessed by navigating to
the Cooling Module screen and then pressing the ENTER key. The following screen will then appear.
Status
Setpoints
Cool Stage Up
XXX Sec
Adjust the desired Cooling Stage Up Delay time and then press the
ENTER key.
Cooling Stage Down Delay
Press the down SELECT arrow key until “Setpoints” is on the top line
of the screen and then press the ENTER key. Press the down SELECT
arrow key or up SELECT arrow key to move forward or backward
through the Cooling Module Setpoint screens.
Please see the Appendix section in the back of this manual for Tables
listing the minimum, maximum and default setpoints for all of the
setpoint screens.
Cooling Stages Quantity
Cool Stages
X
Adjust the quantity of Cooling Stages or Steps of Cooling and then
press the ENTER key.
Outdoor Air Temperature Cooling Lockout
OAT Cool Lockout
XXX F
Adjust the Outdoor Air Temperature Cooling Lockout and then press
the ENTER key.
Cooling Minimum Off Time
Cool Min Off
XXX Sec
Adjust the desired Cooling Minimum Off Time and then press the
ENTER key.
14
Cool Stage Down
XXX Sec
Adjust the desired Cooling Stage Down Delay time and then press the
ENTER key.
Low Pressure Switch Delay
LPS Delay
XXX Sec
The Low Pressure Switch Delay time is a factory setting and should not
be changed unless authorized to do so by WattMaster or AAON® Technical Support.
Low Pressure Switch Safety Delay
LPS Safety
XX Sec
The Low Pressure Switch Safety Delay time is a factory setting and
should not be changed unless authorized to do so by WattMaster or
AAON® Technical Support.
LPS Maximum Trips
LPS Max trips
XX
The Low Pressure Switch Max Trips is a factory setting and should not
be changed unless authorized to do so by WattMaster or AAON® Technical Support.
HB Mini Controller
Technical Guide
Cooling Fan Off Delay
Heating Stage 3 Energized
Cool Fan Off Dly
XXX Sec
The Cooling Fan Off Delay is a factory setting and should not be
changed unless authorized to do so by WattMaster or AAON® Technical Support.
W3-Active
NO
Line #2 displays “YES” if there is a 24 VAC signal on HB Mini Controller terminal “W3”.
Fan Status
Auto Stage Up Time
Fan Status
Fan Off
Auto Stage Up
XXX Sec
The Auto Stage Up Time can be adjusted on this screen when you are
using a single-stage thermostat with a multi-stage HB unit.
Line #2 displays the current Supply Fan Status. If the Supply Fan is
on, line #2 displays either “Fan Low Speed” or “Fan High Speed”.
Heating Relay #1
Heating Module Status Screens
Heat 1 Relay
OFF
The Heating Module Status Screens are accessed by navigating to the
Heating Module screen and pressing the ENTER key. The following
screen will then appear.
Line #2 displays “ON” if Heating Relay #1 is active.
Status
Setpoints
Heating Relay #2
Heat 2 Relay
OFF
Select “Status” by pressing the ENTER key. Press the up or down SELECT arrow key to move forward or backward through the Heating
Module Status screens.
Line #2 displays “ON” if Heating Relay #2 is active.
Heating Stage 1 Energized
W1-Active
NO
Line #2 displays “YES” if there is a 24 VAC signal on HB Mini Controller terminal “W1”.
Heating Stage 2 Energized
W2-Active
NO
Heating Relay #3
Heat 3 Relay
OFF
Line #2 displays “ON” if Heating Relay #3 is active.
Heat Safety Monitor
HSM
CLOSED
Line #2 displays “OPEN” anytime the Heat Safety Monitor is open.
Line #2 displays “YES” if there is a 24 VAC signal on HB Mini Controller terminal “W2”.
HB Mini Controller
15
Technical Guide
Programming With The HB Service Tool
Heating Module Setpoint Screens
The Heating Module Setpoints Screens are accessed by navigating to
the Heating Module and then pressing the ENTER key. The following
screen will then appear.
Status
Setpoints
Heating Stage Up Delay
Heat Stage Up
XXX Sec
Adjust the desired Heating Stage Up Delay time and then press the
ENTER key.
Heating Stage Down Delay
Press the down SELECT arrow key until “Setpoints” is on the top line
of the screen and then press the ENTER key. Press the down SELECT
arrow key or up SELECT arrow key to move forward or backward
through the Heating Module Setpoint screens.
Please see the Appendix section in the back of this manual for Tables
listing the minimum, maximum and default setpoints for all of the
setpoint screens.
Heating Stages Quantity
Heat Stages
X
Adjust the quantity of Heating Stages and then press the ENTER key.
Heat Stage Down
XXX Sec
Adjust the desired Heating Stage Down Delay time and then press the
ENTER key.
Heat Safety Monitor Maximum Trips
HSM Max Trips
X
The Heating Safety Maximum Trips is a factory setting and should not
be changed unless authorized to do so by WattMaster or AAON® Technical Support.
Outdoor Air Temperature Heating Lockout
OAT Heat Lockout
XXX F
Adjust the Outdoor Air Temperature Heating Lockout and then press
the ENTER key.
Heating Fan Off Delay
Heat Fan Off Dly
XXX Sec
The Heating Fan Off Delay is a factory setting and should not be changed
unless authorized to do so by WattMaster or AAON® Technical Support.
Heating Minimum Off Time
Heat Min Off
XXX Sec
Adjust the desired Heating Minimum Off Time and then press the
ENTER key.
Auto Stage Up Time
Auto Stage Up
XXX Sec
The Auto Stage Up Time can be adjusted on this screen when you are
using a single-stage thermostat with a multi-stage HB unit.
Heating Minimum On Time
Heat Min On
XXX Sec
Alarm Module Status Screens
The Alarm Module Status Screens are accessed by navigating to the
Alarm Module and pressing the ENTER key. Setpoints are not available for the Alarm Module. After pressing ENTER the following screen
will appear.
Adjust the desired Heating Minimum On Time and then press the ENTER key.
16
HB Mini Controller
Technical Guide
HSM Lockout
Clogged Filter
HSM Lockout
NO
Line #2 displays “YES” when the Heat Safety Monitor has tripped more
than the HSM Max Trips setpoint.
HPS Fault
Clogged Filter
NO
Line #2 displays “YES” if there is a 24 VAC signal on the Clogged
Filter Input.
HVAC Test Module Screens
HPS Fault
NO
Line #2 displays “YES” when the High Pressure Switch is open and
a Cooling Relay is active.
The HVAC Test Module screens are accessed by navigating to the HVAC
Test Module screen and pressing the ENTER key. After pressing ENTER the following screen will then appear.
Force Time Limit
Force Time Limit
XXX Min
LPS Lockout
LPS Lockout
NO
Adjust the desired time needed for forcing the HB Mini Controller
into an HVAC Test Mode and then press the ENTER key.
Force Relays
Line #2 displays “YES” when the Low Pressure Switch has tripped
more than the LPS Max Trips setpoint.
Force Relays
NO
Bad OAT Sensor
Bad OAT
NO
Line #2 displays “YES” when the Outdoor Air Temperature Sensor is
bad or missing.
Select “YES” to enable Relay Force Mode and then press the ENTER
key.
High Speed Fan Relay Force
HSpd Fan Relay
OFF
OAT Cooling Lockout
OAT Cool Lockout
NO
Select “YES” to activate the High Speed Supply Fan Relay and then
press the ENTER key.
Low Speed Fan Relay Force
Line #2 displays “YES” if the Outdoor Air Temperature is below the
Cooling Lockout Temperature setpoint.
LSpd Fan Relay
OFF
OAT Heating Lockout
OAT Heat Lockout
NO
Select “YES” to activate the Low Speed Supply Fan Relay and then
press the ENTER key.
Line #2 displays “YES” if the Outdoor Air Temperature is above the
Heating Lockout Temperature setpoint.
HB Mini Controller
17
Technical Guide
Programming With The HB Service Tool
Cooling Relay #1 Force
Cool 1 Relay
OFF
Heating Relay #2 Force
Heat 2 Relay
OFF
Select “YES” to activate Cooling Relay #1 and then press the ENTER
key.
Select “YES” to activate Heating Relay #2 and then press the ENTER
key.
Cooling Relay #2 Force
Heating Relay #3 Force
Cool 2 Relay
OFF
Select “YES” to activate Cooling Relay #2 and then press the ENTER
key.
Heat 3 Relay
OFF
Select “YES” to activate Heating Relay #3 and then press the ENTER
key.
Heating Relay #1 Force
Heat 1 Relay
OFF
Select “YES” to activate Heating Relay #1 and then press the ENTER
key.
18
HB Mini Controller
Technical Guide
Troubleshooting
Using LEDs To Verify Operation
The HB Mini Controller is equipped with LEDs that can be used as
very powerful troubleshooting tools. The HB Mini Controller circuit
board has three different colored LEDs. See Figure 8 for the various
LED locations. The Red LED is used to indicate fault conditions. The
Yellow LED indicates the mode of operation the HB Mini Controller is
currently operating in. The Green LED indicates the power and communications status of the HB Mini Controller.
HB Mini Controller Fault Condition Operation
If the Red LED indicates you have a Bad Outdoor Air Temperature
Sensor, heating mode will operate but Cooling Mode will be disabled
until the sensor problem is fixed.
Yellow LED
LED Blinks
1
Mode Indication Description
Vent Mode (Fan Only)
2
Heating Mode
3
Cooling Mode
MHGRV
RESET
ECONO
POS
RAB
LD1 - Red LED
Table 2: Yellow LED Blink Codes
GND
TB2
Green LED
LED Blinks
1
Power/Communications Description
Power Indicator (No Communications)
LD3
LD3 - Green LED
LD2
LD1
LD2 - Yellow LED
2
HSS Communications
TB1
SAT
Table 3: Green LED Blink Codes
GND
HB Controller Board
Figure 8: HB Board LED Locations
One LED blink is defined as a 1 second LED on period immediately
followed by a 1 second LED off period. After each series of blinks is
completed the LED will power off for 3 seconds and then repeat the
series of blinks. The various blink codes and their meanings are defined
in the tables that follow.
Red LED
LED Blinks
1
Fault Condition Description
Heat Safety Lockout
2
High Pressure Fault
3
Low Pressure Lockout
5
Bad Outdoor Air Temperature Sensor
7
Clogged Filter Switch
Notes:
1.) When no fault exists the red LED will be off.
2.) Heat Safety Lockout (1 blink) is the highest priority. Clogged
Filter Switch (7 blinks) is the lowest priority.
Table 1: Red LED Blink Codes
HB Mini Controller
19
Technical Guide
Appendix
The HB Mini Controller has many setpoints that are user adjustable.
This adjustability allows the installer complete control of all major unit
operating characteristics during the setup and commissioning phase of
the HB unit installation. It also allows a service technician the ability to
change setpoints to monitor and record unit operation to determine if
the unit is functioning as specified. The tables that follow show the
available setpoints for each classification or control group provided on
the HB Mini Controller.
Cooling Control Setpoints
Description
Min.
Default
Cooling Stages
1
2
Minimum Off Time
180 Sec
180 Sec
Minimum On Time
300 Sec
300 Sec
Staging Up Delay Interval
180 Sec
180 Sec
Staging Down Delay Interval
60 Sec
60 Sec
Low Pressure Delay Period
5 Sec
30 Sec
Low Pressure Safety
5 Sec
5 Sec
Low Pressure Max. Trip Point
1
3
Fan Off Delay Period
1 Sec
45 Sec
Auto Staging Up Delay
180 Sec
600 Sec
Temperature
Description
Cooling Lockout
Temperature
Heating Lockout
Temperature
Control Setpoints
Min.
Default
32° F
40° F
Max.
80° F
40° F
120° F
80° F
Table 6: Temperature Control Setpoints
Max.
2
900 Sec
900 Sec
900 Sec
900 Sec
60 Sec
30 Sec
5
120 Sec
900 Sec
Miscellaneous Control Setpoints
Description
Min.
Default
Max.
Force Mode Timer
1 Min
60 Min
240 Min
Table 7: Miscellaneous Control Setpoints
Table 4: Cooling Control Setpoints
Heating Control Setpoints
Description
Min.
Default
Heating Stages
1
3
Minimum Off Time
60 Sec
60 Sec
Minimum On Time
120 Sec
120 Sec
Staging Up Delay Interval
180 Sec
180 Sec
Staging Down Delay Interval
60 Sec
60 Sec
Heat Safety Maximum Count
1
3
Fan Off Delay Period
1 Sec
120 Sec
Auto Stage Up Delay
180 Sec
600 Sec
Max.
3
900 Sec
900 Sec
900 Sec
900 Sec
5
180 Sec
900 Sec
Table 5: Heating Control Setpoints
20
HB Mini Controller
Technical Guide
Temperature – Resistance – Voltage For Type III 10 K Ohm Thermistor Sensors
Temp
Resistance
Temp
Resistance
(Ohms)
Voltage @
Input (VDC)
(ºF)
-10
-5
0
5
10
15
20
25
30
35
40
45
50
52
54
56
58
Temp
Resistance
(Ohms)
Voltage @
Input (VDC)
(ºF)
(Ohms)
Voltage @
Input (VDC)
(ºF)
93333
80531
69822
60552
52500
45902
40147
35165
30805
27140
23874
21094
18655
17799
16956
16164
15385
2.98
2.94
2.89
2.83
2.77
2.71
2.64
2.57
2.49
2.41
2.33
2.24
2.15
2.11
2.08
2.04
2.00
60
62
64
66
68
69
70
71
72
73
74
75
76
78
80
82
84
14681
14014
13382
12758
12191
11906
11652
11379
11136
10878
10625
10398
10158
9711
9302
8893
8514
1.96
1.93
1.89
1.85
1.81
1.79
1.78
1.76
1.74
1.72
1.70
1.68
1.66
1.63
1.59
1.55
1.52
86
88
90
95
100
105
110
115
120
125
130
135
140
145
150
8153
7805
7472
6716
6047
5453
4923
4449
4030
3656
3317
3015
2743
2502
2288
1.48
1.45
1.41
1.33
1.24
1.16
1.09
1.02
0.95
0.88
0.82
0.76
0.71
0.66
0.61
Thermistor Sensor Testing Instructions
1.) Use the resistance column to check the thermistor sensor while disconnected from the controllers (not powered).
2.) Use the voltage column to check sensors while connected to powered controllers. Read voltage with meter set on DC volts. Place
the “-”(minus) lead on GND terminal and the “+”(plus) lead on the sensor input terminal being investigated.
If the voltage is above 3.3 VDC, then the sensor or wiring is “open.” If the voltage is less than 0.05 VDC, the sensor or wiring is shorted.
Table 8: Temperature Sensor - Voltage & Resistance for Type III Sensors
HB Mini Controller
21
Technical Guide
Notes:
22
HB Mini Controller
Technical Guide
HB Mini Controller
23
Form: AA-HBM-TGD-01A
All rights reserved
AAON, Inc.
Printed in the USA
WattMaster Controls Inc. • 8500 NW River Park Drive
Phone (816) 505-1100
www.wattmaster.com
•
November 2005
Copyright 2005
Parkville, Mo. • 64152
Fax (816) 505-1101
2425 So. Yukon Ave • Tulsa, OK 74107-2728
Ph: (918) 583-2266 • Fax: (918) 583-6094
AAON® Part No. R38860
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