INSTRUCTION MANUAL
Air Conditioner
HB16 Series
Protecting Electronics.
Exceeding Expectations.™
Pentair Equipment Protection
2100 Hoffman Way
Minneapolis, MN 55303 USA
+1.763.422.2211
+1.763.576.3200
PentairEquipmentProtection.com
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TABLE OF CONTENTS
UNPACKING AND INSPECTING...................................................................................................................................................................... 2
HANDLING............................................................................................................................................................................................................ 3
HOW TO IDENTIFY YOUR HIBOY® AIR CONDITIONER............................................................................................................................. 3
TECHNICAL INFORMATION............................................................................................................................................................................. 4
Design Data.................................................................................................................................................................................................. 4
Bench Testing............................................................................................................................................................................................... 5
INSTALLATION INSTRUCTIONS.............................................................................................................................................................. 6
Mounting Inside of the Enclosure................................................................................................................................................ 6
Mounting on Top of the Enclosure............................................................................................................................................... 7
PRINCIPLES OF OPERATION.................................................................................................................................................................... 8
MAINTENANCE............................................................................................................................................................................................ 9
Compressor........................................................................................................................................................................................... 9
Inlet Filter............................................................................................................................................................................................... 9
Condenser and Evaporator Blowers............................................................................................................................................ 9
Refrigerant Loss................................................................................................................................................................................... 9
How to Remove, Clean or Install a New Filter.........................................................................................................................10
Dimensional Drawings...........................................................................................................................................................................11
Parts List.......................................................................................................................................................................................................12
Accessories..................................................................................................................................................................................................12
Parts Exploded View................................................................................................................................................................................13
Wiring Schematic.....................................................................................................................................................................................14
Electrical Schematic.................................................................................................................................................................................15
WARRANTY.........................................................................................................................................................................................................18
HOLD HARMLESS..............................................................................................................................................................................................19
WARNING
Read this manual thoroughly before attempting to install or test
this HIBOY® air conditioner
UNPACKING AND INSPECTING
Inspect the HIBOY® air conditioner. Check for concealed damage that may have occurred during shipment. Look for
dents, scratches, loose assemblies, evidence of oil, etc. Any damage evident upon receipt should be noted on the
freight bill. Damages should be brought to the attention of the delivering carrier within 15 days of delivery and NOT to
Pentair Technical Products. Save the carton and packing material and request an inspection. Then file a claim with the
delivering carrier.
Pentair Technical Products cannot accept responsibility for freight damages; however, we are ready to assist you in any
way possible.
NOTE: Some of the information in this manual may not apply if a special unit was ordered. If
additional drawings for a special unit are necessary, they have been inserted. Contact Pentair
Technical Products if further information is required.
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HANDLING
To avoid possible shipping damage and facilitate transportation and storage, the HIBOY® air conditioner was shipped
in a freight carrier tested corrugated container in its normal mounting position. After uncartoning, be certain that the
air conditioner is placed in its normal upright mounting position for a minimum of five (5) minutes before operating, in
order to allow the compressor oil to drain to the compressor sump area.
CAUTION
Do not attempt to operate the air conditioner while it is horizontal
or on its side, back or front. The refrigeration compressor is filled
with lubricating oil. This will cause permanent damage to the air
conditioner and also voids the warranty.
HOW TO IDENTIFY YOUR HIBOY® AIR CONDITIONER
For installation and maintenance as outlined in this manual, first refer to the nameplate on your unit. The nameplate
will provide important data regarding capacity of the unit, minimum and maximum ambient operating temperatures,
type and amount of refrigerant required for recharging, and most important - electrical power characteristics when
making electrical hook-ups or connections.
)
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TECHNICAL INFORMATION
Design Data
Full Load
Amps
Phase
BTU/Hr. @
Maximum Ambient
Temperature
Maximum
°F Ambient
Temperature
50/60
18.8/20.4
1
7075/8133
131
145/66
230
50/60
9.4/10.2
1
7075/8133
131
145/66
460
50/60
5.2/5.6
1
7075/8133
131
160/73
Model
Voltage
HB160816GXXX
115
HB160826GXXX
HB160846GXXX
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Shipping Weight
(lb. / kg)
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Bench Testing
CAUTION
To avoid possible damage to the air conditioner, it must be in
an upright operating position for a minimum of five (5) minutes
before functional testing is started.
When “bench testing the HIBOY® air conditioner before mounting to the electronic enclosure, follow the procedures
outlined in the following paragraphs:
Make sure that the HIBOY® air conditioner is supported in a manner that assures free air flow out of and back
into the openings which are located in the base tray.
Refer to nameplate for proper electrical current requirements, then connect the power cord to a properly
grounded electrical outlet.
NOTE: Minimum circuit ampacity should be at least 125% of the amperage shown in the DESIGN
DATA table. To prevent overloading, no other equipment should be connected to this circuit.
Make sure the unit has been in the upright operating position for at least five minutes.
Operate the air conditioner for five (5) or ten (10) minutes. No excessive noise or vibration should be evident
during this run period. The condenser blower located in the rear section of the air conditioner, the evaporator
or cool air blower located in the bottom of the unit, and the compressor should be running. To check cool air
output, use a reliable air temperature measuring device. The cool air should be between 50 F (10 C) and 60 F
(16 C) when room temperature is between 70 F (21 C) and 80 F (27 C).
You may remove the air inlet filter while checking the operation. The discharge line from the compressor
(uninsulated line) should become very warm. Carefully touch this line to avoid possible burns. Condenser air
temperatures should be warmer than normal room temperatures within a few minutes.
Mounted along the side of the compressor is the suction accumulator which is insulated to help avoid
sweating or condensation buildup.
The compressor is provided with automatic reset thermal overload protection. This thermo switch is located
and mounted inside the plastic enclosure clipped to the compressor. The only time this switch should operate
is when the compressor overheats due to clogged or dirty inlet air filter, if ambient air temperatures exceed
nameplate rating or if enclosure dissipated heat loads exceed the rated capacity of the air conditioner. The
thermal overload switch will actuate and stop compressor operation. Blowers will continue to operate,
however, and the compressor will not restart until the compressor has cooled to within the thermal overload
cut-in temperature setting.
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INSTALLATION INSTRUCTIONS
Mounting Inside of the Enclosure
1. Slide rails must be provided for supporting the rear portion of the air conditioner. Do not depend on
the units mounting flange to support the entire weight. For mounting opening cutout dimensions, see
Figure 2.
2. To protect the integrity of the closed-loop design (see PRINCIPLES OF OPERATION, page 8), adhesive
backed gasket tape is provided (shipped loose) for sealing around the enclosures air conditioner
mounting opening. The gasket tape may be cut to length and either adhered to the air conditioner or
to the enclosure as preferred.
3. The hot condenser air from the rear of the air conditioner must be ducted out of the enclosure.
Openings and/or ducting must be of sufficient size to handle the air flow (25 in.2 minimum). Keep in
mind that reduction of air flow will impair air conditioner performance. Also remember that this air is
hot and relatively dirty, therefore cracks and joints must be adequately sealed.
4. The drain tube which exits at the side of the air conditioner must be routed to the exterior of the
enclosure. A copper “P” trap has been included in the drain system and must be properly primed and
installed to prevent counter air flow into the drain system. A pressure relief fitting is also provided to
vent any air blockage that may prevent proper drainage. The drain outlet must not be submerged nor
any portion of the drain system elevated above the exit point of the air conditioner or overflowing of
the condensate pan may occur.
5. Use of extension cords is not recommended.
Cutout Dimensions for NEMA 12 Enclosures
Dashed Lines Repersent Air Conditioner
Figure 2
Mounted Inside Enclosure
Figure 1
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Mounting on Top of the Enclosure
1. Make sure the enclosure design is capable of supporting the air conditioners weight. For interfacing air
“IN” and “OUT” openings, refer to Figure 4. Also refer to Dimensional Drawings on page 11.
2. To protect the integrity of the closed-loop design (see PRINCIPLES OF OPERATION), adhesive backed
gasket tape is provided (shipped loose) for sealing around the enclosures cutout openings. The gasket
may be cut to length and either adhered to the enclosure or to the air conditioner as shown in Figure
5.
3. A .5 inch (13 mm) inside diameter drain tube exists on the side of the air conditioner and must be
routed over the side. A pressure relief fitting has been provided to assist in venting any air blockage
that may prevent proper drainage. A copper “P” trap has also been included in the system and must
be properly primed and installed to prevent counter air flow into the drain system. The drain outlet
must not be submerged nor any portion of the drain system elevated above the exit point of the air
conditioner or overlapping of the condensate pan may occur.
Mounted on Top of Enclosure
Figure 3
Gasket Installation
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Cutout Dimensions for Top Surface Mounting
Dashed Lines Repersent Air Conditioner
Figure 4
Outside of Enclosure
Through Enclosure
Drain System
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PRINCIPLES OF OPERATION
HIBOY® air conditioners are designed specifically to cool and dehumidify the internal environments of cabinets and
enclosure which are used to package electronic components, thus assuring a cool, clean atmosphere for reasons of
optimum performance and longevity.
Hot air inside the electronic enclosure or rack is removed and cooled by means of refrigeration. The hot air is drained
from the enclosure interior through the evaporator air return opening in the bottom middle of the air conditioner. The
air is drawn through the evaporator coil where it is cooled and discharged back to the enclosure interior through two
evaporator outlet openings in the bottom rear of the unit. Any moisture in this air condenses on the evaporator coil
and ultimately collects in the condensate tray where it is then discharged from the air conditioner via the condensate
drain tube.
The closed-loop design of the air conditioner assures that this clean, cooled air never mixes with the hot, dirty ambient
air that is used only for cooling the compressor and accomplish the heat exchange through the condenser coil.
Generally the cabinet or enclosure air which is being cooled and recirculated over and over again does not require any
filtering media.
Room or ambient air drawn into the air conditioner through the inlet filter, across the compressor and through the
condenser coil is usually dirty, dusty and/or humid air depending upon the specific environment in which the air
conditioner is required to operate. This ambient air is discharged by the condenser duplex blower back to the ambient
environment. The temperature of this discharged air will be quite warm or actually hot depending on the ambient
temperature and the work load imposed on the air conditioner.
Provided the inlet filter is properly maintained by frequent cleaning and/or replacement, the inlet filter will assure
relatively clean air to pass through the condenser coil. Dirty filters will hamper the optimum operating efficiency of
the air conditioner.
NOTE: The condenser filter will require periodic maintenance, see MAINTENANCE on page 9.
When the HIBOY® air conditioner is mounted in the enclosure or rack, it is recommended that an electrical lockout or
safety switch be installed to interrupt operation of the unit while the enclosure door is opened.
If electrical power is momentarily interrupted to the air conditioner and reapplied immediately (within 3 to 5
seconds)., the compressor may not restart due to the high back pressure of the compressor.
DO NOT attempt to restart the air conditioner for at least one minute after the unit has been
shut off either accidentally or intentionally.
It takes at least one minute after shut-down for the compressor suction and discharge pressure to equalize in order to
restart the air conditioner.
Operating the HIBOY® air conditioner at ambient temperatures below the minimum or above
maximum temperatures indicated on the nameplate will void all warranties.
It is recommended that the warranty section of this manual be read in order to familiarize
yourself with parameters of restricted operation.
It is very important to install the drain system in accordance with the installation instructions on page 7. By elevating
the drain tube above the exit point on the air conditioner, you will cause the collected condensate or water to back
up the drain tube and flood the condensate tray. This flooding or overflowing water could be transmitted into
the electronic cabinet or enclosure by the air exhausted from the evaporator blower, thus causing damage to the
expensive electronic components.
The moisture that the enclosure air can contain is limited. If moisture flows from the drain tube continuously, this can
only mean ambient air is entering the enclosure. Remember frequent opening of the enclosures door admits humid
air which the air conditioner must then dehumidify.
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MAINTENANCE
Compressor
The compressor requires no maintenance. It is hermetically sealed, properly lubricated at the factory and
should provide years of satisfactory operating service.
Should the freon charge be lost, recharging ports (access fittings) on the suction and discharge sides of the
compressor are provided for recharging and/or checking suction and discharge pressures.
Under no circumstance should the access fitting covers be loosened, removed or tampered
with.
Recharging ports are provided for the ease and convenience of reputable refrigeration repair service
personnel for recharging the air conditioner, see Refrigerant Loss.
Inlet Filter
Proper maintenance of the inlet filter will assure normal operation of your HIBOY® air conditioner. If filter
maintenance is delayed or ignored, the maximum ambient temperatures under which the unit is designed to
operate will be decreased.
As the compressor operating temperature increases above normal due to dirty or clogged inlet filter (or
plugged condenser coil), the air conditioners compressor will stop operating due to actuation of the thermal
overload cutout switch located on the compressor housing. As soon as the compressor temperature has
dropped to within the switches cut-in setting, the compressor will restart automatically. However the above
condition will continue to take place until the inlet filter has been cleaned or replaced.
It is recommended that power to the air conditioner be interrupted intentionally when abnormally high
compressor operating temperatures cause automatic shut-down of the unit. The above described shut-down
is symptomatic of a clogged or dirty filter, thus causing a reduction in cooling air flow across the surface of the
compressor and condenser coil.
Continued operation under the above conditions will damage and shorten the compressor life.
The air conditioner features an easily removable inlet filter to facilitate necessary cleaning.
There should be no reason to neglect this necessary maintenance.
Condenser and Evaporator Blowers
Blower motors require no maintenance. All bearings, shafts, etc. are lubricated during manufacturing for the
life of the motor.
CAUTION
Operation of the HIBOY® air conditioners in areas containing
airborne caustics or chemicals can rapidly deteriorate filters,
condenser coils, blowers and motors, etc. Contact Pentair
Technical Products for special recommendations.
Refrigerant Loss
Your HIBOY® air conditioner was thoroughly tested before leaving the factory to insure against refrigeration
leaks. Shipping damage or microscopic leaks not found with sensitive electronic freon leak detection
equipment during manufacture may require repair and recharging of the system. This work should be
performed by a qualified professional only, generally available in any reputable air conditioning repair or
service company in your local area.
Refer to the data on your nameplate which specifies the type of freon and the charge size in
ounces.
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recharging, make sure there are no
leaks and the system has been properly evacuated
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-9-
How to Remove, Clean or Install a New
Filter
1. Lift the filter up so the bottm clears the
lower filter retainer.
2. Pull the bottom of the filter out while
pushing down until the top of the filter
clears the upper retainer. If the unit is
operating, carefully remove it assuring
no dirt from the filter enter the air intake
opening.
3. Follow the cleaning instructions shown in
the graphic below.
4. Look at the air flow arrows on the filter for
correct installation direction. Reinstall the
cleaned filter (or a new filter) by sliding
the top of the filter up into the upper
retainer while pushing it against the unit.
Finally, slide the filter down into the lower
retainer.
For replacement filter, disposable filters and filter adhesive, see parts list in Table 1 on page 12
RP aluminum washable air filters are designed to provide
excellent filtering efficiency with a high dust holding capacity
and a minimum amount of resistance to air flow. Because they
are constructed entirely of aluminum, they are light weight
and easy to service. Optimum filter performance is
maintained by recoating the filters after washing with RP
Super Filter Coat adhesive. To achieve maximum performance
from your air handling equiment, the air filter should be
cleaned on a regular basis.
1. Flush the filter with warm water from the exhaust
side to the intake side. DO NOT use caustics.
2. After flushing, allow filter to drain. Placing it with
a corner down will assure complete drainage.
3. Recoat the filters with RP Super Filter Coat
adhesive by dipping or spraying. If the filter is
sprayed, do so from both sides for maximum
concentration of adhesive.
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Dimensional Drawings
HB16 Models 8000 BTUs/Hr. (2051 Watts)
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Parts List
(Specify model and serial numbers when ordering parts)
Item Number
Part Number
Quantity
Description
1
10-1000-08
1
Inlet Filter, Reusable Aluminum
9
16-7001-00
1
Coil, Condenser
16
52-6034-10M
1
Blower, Condenser (115 V)
52-6025-10M
1
Blower, Condenser (230 V)
52-6075-00
1
Blower, Evaporator (115 V)
52-6076-00
1
Blower, Evaporator (230 V)
26
52-6121-01
1
Coil, Evaporator (8000-9000 BTU/Hr.)
30
52-6058-05
1
Accumulator (230V Only)
35
See Table 1
1
Switch, Compressor Thermal Overload
38
See Table 1
1
Compressor
39
See Table 1
1
Power Cord
47
52-6028-00
1
Filter/Dryer, Refrigerant
48
52-6027-00
1
Valve, Hot Gas By-Pass (230V Only)
49
See Table 1
1
Capacitor, Compressor
N/A
10-1040-47
1
RFG, TXV (115V Only)
23
Accessories
Part Number
Description
23512
Filter Coat - 1 pint Spray Dispenser
Table 1
Model
Item 35 Overload
Item 38 Compressor
Item 39 Power Cord
Item 49 Capacitor
HB160816GXXX
89097975
89043892
52-6035-85
52-6032-01
HB160826GXXX
10-1007-13
10-1026-115
52-6035-141
52-6031-01
HB160846GXXX
10-1007-13
10-1026-115
52-6035-135
52-6031-01
NOTE: For items listed but not shown, contact the factory..
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Parts Exploded View
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Wiring Schematic
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Electrical Schematic
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Notes
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Notes
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WARRANTY
A.
B.
C.
D.
E.
Please note: Warranty effective at time of shipment. Pentair Technical Products warrants that all material and
workmanship are free of defects in quality which impair the usefulness of the thermoelectric cooler or heat
exchanger for a period of five (5) years for nonoperating parts, except for the filter; and for one (1) year for
everything else when installed and operated under the following conditions:
Maximum voltage variation no greater than plus or minus 10% of nameplate nominal rating.
Maximum frequency variation no greater than plus or minus 3 Hz. of nameplate nominal rating.
Must not exceed minimum and maximum stated temperatures on the nameplate.
Not to exceed (BTU/Hr.) rating, including any heat sink, as indicated on the nameplate.
The unit must not be restarted for a period of one (1) minute after intentional or accidental shut-off. (This
does not apply to heat exchanger or filter fan.)
Pentair Technical Products warrants that all material and workmanship are free of defects in quality which
impair the usefulness of the filter fan package and all custom thermoelectric coolers and heat exchangers for a
period of one (1) year, except for the filter, when installed and operated under conditions A, B, C and D as listed
above.
Not covered in this warranty is damage to the thermoelectric cooler or heat exchanger due to the introduction
of other than the nameplate-designated refrigerant. Operation of any Pentair Technical Products product that
has not been designed with proper protective coatings and/or options and is in an abnormal or corrosive
environment voids the warranty. Prolonged operation with dirty filters also voids the warranty.
Should any part prove defective within the above warranty period, the customer may choose to return the
defective product that is under warranty to Pentair Technical Products for repair at no charge or the customer
has the option to repair the defective products at his own expense and Pentair Technical Products will supply
repair parts at no charge providing the defective part is returned and found to have failed under warranty.
Parts supplied as warranty replacement parts will assume the balance of the warranty on the part returned for
warranty consideration.
Please be advised: According to the Federal Register, no person maintaining, servicing, repairing, or disposing
of appliances may knowingly vent or otherwise release into the environment any class I or class II substance
used as refrigerant.
Pentair Technical Products assumes no liability beyond the repair or replacement of its own product. Customer
modification of any Pentair Technical Products product voids this warranty.
The purchaser assumes the responsibility of grounding the unit and installing it in accordance with local
electrical and safety codes, as well as the National Electric Code (NEC) and OSHA.
This express warranty constitutes the entire warranty with respect to the PRODUCT and IS IN LIEU OF ALL
OTHERS, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OR MERCHANTABILITY AND WARRANTY OF
FITNESS FOR A PARTICULAR PURPOSE AND IN NO EVENT IS PENTAIR TECHNICAL PRODUCTS RESPONSIBLE FOR
ANY CONSEQUENTIAL DAMAGES OF ANY NATURE WHATSOEVER.
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HOLD HARMLESS
In consideration of purchase of equipment from Pentair Technical Products by a customer, Pentair Technical
Products agrees to indemnify and hold harmless such customer and users with a defense, as to any claim,
demand, statutory court cost, fees for attorney’s services provided for below, and/or judgment, for actual of
alleged patent infringement in any country, arising out of the use, sale or advertisement of any equipment
manufactured or sold by Pentair Technical Products to Pentair Technical Products’s own specifications,
provided that the customer or user shall promptly notify Pentair Technical Products in writing of any
such claim or demand, provided further that Pentair Technical Products shall have the right and option to
undertake and control the entire defense of such claim, or demand instituted against the customer or user,
but limited to the products made or sold by Pentair Technical Products, through counsel selected by Pentair
Technical Products, and to settle and pay any claim award arising out of such claim or demand, and provided
further that the customer or user will provide such information and assistance as Pentair Technical Products
may request subject to reimbursement by Pentair Technical Products for any out-of pocket expense incurred
in providing such requested assistance. Liability of Pentair Technical Products for any infringement or claim
thereof shall be limited to the above undertaking.
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Protecting Electronics.
Exceeding Expectations.™
Pentair Equipment Protection
2100 Hoffman Way
Minneapolis, MN 55303 USA
+1.763.422.2211
+1.763.576.3200
PentairEquipmentProtection.com
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