Orion HB Controller User Manual
HB Controller
Technical Guide
Table of Contents
Controller Overview ......................................................................................................................................... 3
General ........................................................................................................................................................................................3
Inputs ...........................................................................................................................................................................................3
Outputs ........................................................................................................................................................................................3
Controller Sequence of Operation .................................................................................................................. 4
Fan Mode .....................................................................................................................................................................................4
Heating Mode ..............................................................................................................................................................................4
Cooling Mode ..............................................................................................................................................................................4
Economizer Cooling ...................................................................................................................................................................4
General Economizer Operation.............................................................................................................................................4
Economizer Operation with ECS Control ............................................................................................................................. 4
Mechanical Cooling Staging with ECS Control .....................................................................................................................4
Economizer IAQ Control ...........................................................................................................................................................4
Economizer Dehumidifi cation ...................................................................................................................................................4
1-or 2-Stage Cooling Units with Adjustable Two-Speed or Two-Speed Supply Fan Control ................................................4
Dehumidifi cation Mode (No Reheat) .........................................................................................................................................5
Dehumidifi cation Mode with Hot-Gas Reheat ..........................................................................................................................5
1-Stage Cooling with Adjustable Two-Speed or Two-Speed Supply Fan Control ................................................................. 5
2-Stage Cooling with Adjustable Two-Speed or Two-Speed Supply Fan Control ................................................................ 5
Lockout Modes ...........................................................................................................................................................................5
SAT Lockout Modes ...................................................................................................................................................................6
Exhaust Fan Control .................................................................................................................................................................. 6
HB Processor Board .................................................................................................................................................................. 6
Controller Installation & Wiring ...................................................................................................................... 7
Programming with the HB Service Tool ........................................................................................................ 14
Optional MHGRV Module Settings ................................................................................................................. 34
Troubleshooting ............................................................................................................................................. 36
Appendix ........................................................................................................................................................ 37
Index .............................................................................................................................................................. 42
Space Temperature Control Sequence ................................................................................................................................. 6
Controller Mounting ...................................................................................................................................................................7
Important Wiring Considerations .............................................................................................................................................7
Entering Passcodes .................................................................................................................................................................14
General Procedures ................................................................................................................................................................. 14
Module Selection Screens ..................................................................................................................................................14
HB Controller Status & Setpoints ..........................................................................................................................................15
Main Status Screens ...........................................................................................................................................................15
Fan Module Status Screens ................................................................................................................................................16
Fan Module Setpoint Screens .............................................................................................................................................16
Cooling Module Status Screens ..........................................................................................................................................17
Cooling Module Setpoint Screens .......................................................................................................................................18
Heating Module Status Screens..........................................................................................................................................19
Heating Module Setpoint Screens.......................................................................................................................................20
Economizer Module Status Screens ................................................................................................................................... 21
Economizer Module Setpoint Screens ................................................................................................................................ 22
Dehumidify Module Status Screens .................................................................................................................................... 23
Alarm Module Status Screens.............................................................................................................................................24
Force Mode Module Screens .............................................................................................................................................. 25
Force Mode Module Setpoint Screens ................................................................................................................................26
Factory Options Module Screens ................................................................................................
........................................27
HB Processor Board ................................................................................................................................................................ 28
HB Processor Board Status Screens .................................................................................................................................. 28
HB Processor Setpoint Screens..........................................................................................................................................29
HB Processor Week Schedule Module Screens .................................................................................................................30
HB Processor Real Time Clock Module Screens ................................................................................................................ 31
Hot Gas Reheat Controller ......................................................................................................................................................32
Hot Gas Reheat Status Screens ......................................................................................................................................... 32
Supply Air Temperature ...........................................................................................................................................................34
Supply Air Temperature Reset Limit ...................................................................................................................................... 34
Using LEDs To Verify Operation ............................................................................................................................................. 36
HB Controller Fault Condition Operation.............................................................................................................................36
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: mail@wattmaster.com
Visit our web site at www.wattmaster.com
Form: AA-HB-TGD-01E Copyright 2009 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.
Overview
Controller Overview
General
The HB Controller is designed to work with a normal 24 VAC Thermostat
and Dehumidistat. 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. Fan speed can be adjusted for both high and low
speeds by way of an interface when the HB unit is equipped with an
adjustable speed controller. Dehumidifi cation is optimized by use of a
Return Air Bypass damper. Modulating Hot-Gas Reheat can be used to
reheat the Supply Air during Dehumidifi cation.
A CO2 sensor can be connected through the wiring harness when IAQ
control is desired. Also, two damper positions are available when using
Two-Speed Supply Fans, thus providing enhanced IAQ control.
The HB Controller also monitors equipment safeties, logs information,
and locks out the equipment in the event of multiple failures. All sensors are needed in order to provide all modes of operation. However, to
prevent a potential freeze condition, Heating Mode will still operate if
all sensors have failed or are missing.
Terminal block style connections are provided for fi eld wiring of the
Thermostat, Dehumidistat, and Supply Air Temperature Sensor wires.
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
RH: Dehumidistat
SAT: Supply Air Temperature Sensor
MHGRV Reset: Modulating Hot-Gas Reheat Signal (0-10VDC)
RAB: Return Air Bypass Damper Actuator (by others)
ECS: (Enthalpy Changeover Switch)
Econo Pos: Economizer Control (by others)
Carbon Dioxide Sensor
Outdoor Air Temperature Sensor
Liquid Line Temperature Sensor (currently not used)
Heat Safety Monitor (monitors main and auxiliary limit thermostats)
High-Pressure Switch
Low-Pressure Switch
Clogged Filter Switch
Outputs
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
Condenser Fan Relay
AUX: Currently used for an exhaust fan relay
Modulating Hot-Gas Reheat Signal (from HGR controller)
Adjustable Two-Speed Fan Signal (0-10VDC)
Return Air Bypass Damper Actuator (0-10VDC)
Economizer Damper Actuator (2-10VDC)
Modulating Hot-Gas Reheat Reset Signal (0-10 VDC)
A1, A2: Economizer 24 VAC Power Supply Jumper Terminals
C1, C2: Clogged Filter Switch 24 VAC Output Terminals
PBS
P11
HEATSECTION
PROGRAM
SOCKET
P
V3
V2
6.10"
V1
6.50
SW1
C1
ECONO SECTION
RAB
ECONO
P1
POS
P3
Figure 1: HB Controller Dimensions
8.00"
7.60"
HSS
R71
R11
R13
R8
P8
C5
C37
K4
D1
D21
D20
K2
C2
R1
D1
C4
JO2
JO1
INT
EXT
HSS
1
P6
RN1
7
7
C36
R21
R1
R16
8
R15
R18
R12
R7
R5
R10
C6
C3
R14
R17
R2
R3
D5
R6
R
C7
RAB
MHGRV
RESET
ECONO
POS
C20
R3
C3
C17
C38
C13
4
C43
C11
C8
R22
C10
R20
D6
GND
10
R31
R33
R2
2
C35
C
C16
R30
D7
R23
R25
D
R32
R36
C14
R24
R24
R35
R37
R28
D8
R26
R38
C12
C15
R40
R34
R27
TB2
LD2LD1
8
R74
R75
R72
6
R61
R58
5
C24
X1
C23
C41
R46
R70
3
C34
R41
R4
R42
R44
D11
C18
R43
R45
R47
D10
C1
LD3
R73
C46
C42
C44
C45
R48
C22
D12
TB1
TTL
C40
VR1
R4
R50
C21
R60
R63
R51
R53
R56
R57
D13
C28
C26
R52
R5
R62
R55
D14
R54
C27
C25
R
GND
SAT
D1
1
P7
D3
3
D2
AXCP
2
D18
6
D17
5
D4
4
R65
D16
R64
D15
GND
K5
C32
REV 4
YS101 2
7
D22
HB VB NIT BOARD
MADE IN THE SA
MOD HGR
P5
P5
RH
G
Y1
C2
L1
C30
Y2
W1
W2
W3
P2
V4
V8
V7
V6
V
V5
C31
MC34064A
36
R67
R66
A1
A2
AX
SERIAL #
SECTION
COOLING
P4
I
0
VR2
R68
C33
R6
GND
D23
P10
POWER
24VAC
V10
TB3
C2
C1
HB Controller Technical Guide
3
Sequence of Operations
Controller Sequence of Operations
Fan Mode
The HB Controller supports 2 different Supply Fan confi gurations. It
can be confi gured for Adjustable Two-Speed Fan or Two-Speed 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
If the HB Controller is confi gured 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 Controller is confi gured 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 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.
Economizer Cooling
General Economizer Operation
If the Outdoor Air Temperature is below the Economizer Enable Setpoint
and there is a call on “Y1,” the compressors will be locked out, and the
Economizer will modulate to achieve a 55° F Supply Air Temperature.
If the HB Controller is confi gured for 1 stage of Cooling, on a call for
“Y1,” the Supply Fan will run at High Speed. If the HB Controller is
confi gured for 2 stages of Cooling, on a call for “Y1,” the Supply Fan
will run at low speed. When “Y2” is called, the Supply Fan will go to
high speed.
Economizer Operation with ECS Control
If the Enthalpy Changeover Switch (ECS) is closed and the outdoor air
temperature is below the ECS, OAT Enable setpoint (default 65° F),
the economizer will modulate and attempt to achieve 55° F supply air
temperature. If the outdoor air temperature is above 55° F, the economizer will generally open to 100%. Mechanical cooling can be used
to supplement the economizer if the outdoor air temperature is above
the ECS OAT Enable setpoint and the economizer signal is at 100%.
Once mechanical cooling is activated to supplement the economizer, the
economizer will remain at 100% until the cooling call is satisfi ed.
Mechanical Cooling Staging with ECS Control
If the HB Controller is confi gured for 1 stage of Cooling, on a call for
“Y1,” the Supply Fan will run at High Speed. Cool Stage 1 will activate
after the Cooling Auto Stage-Up Delay. If the HB Controller is confi gured for 2 stages of Cooling, on a call for “Y1,” the Supply Fan will
run at Low Speed. Cool Stage 1 will activate after either the Cooling
Auto Stage-Up Delay Expires or a call for “Y2” is made. When “Y2”
is called, Cool Stage 2 will activate after the Cooling Auto Stage-Up
Delay. After Cool Stage 2 is activated, the Supply Fan will switch to
High-Speed operation.
Economizer IAQ Control
The economizer is also used for CO2 control. If the CO2 level is above
the Minimum CO2 PPM setpoint, the Economizer Minimum Position will
be reset proportionally between the Minimum CO2 PPM and Maximum
CO2 PPM setpoints. When the CO2 level is above the Maximum CO2
PPM setpoint, the Economizer will open as far as the Maximum Damper
Adjustment Position setpoint setting. There are two Minimum and two
Maximum Economizer Damper Positions depending on the Supply Fan
speed. These are the Maximum Damper Position with Low-Speed Fan,
the Minimum Damper Position with Low-Speed Fan, the Maximum
Damper Position with High-Speed Fan, and the Minimum Damper Position with High-Speed Fan. The air balancing contractor should determine
these settings in order to maintain the proper amount of fresh air being
supplied to the building.
Economizer Dehumidifi cation
1-or 2-Stage Cooling Units with Adjustable
Two-Speed or Two-Speed Supply Fan Control
If the Outdoor Air Temperature is below the Economizer Enable Setpoint
and there is a call for Dehumidifi cation on “RH,” the compressors will
be locked out, and the Economizer will modulate to achieve 55° F Supply Air Temperature. The Supply Fan will run at Low Speed, and the
Return Air Bypass will be closed.
For 1 stage Cooling units, on a call for “Y1,” the HB Controller will
enter the Cooling Mode, and the Supply Fan will run at High Speed. The
Cooling Mode will be maintained until “Y1” is satisfi ed. As long as there
is still a call for “RH,” the Dehumidifi cation Mode will resume.
For 2 stage Cooling Units, “Y1” is ignored during this mode to extend
Dehumidifi cation. On a call for “Y2,” the HB Controller will enter the
Cooling mode, and the Supply Fan will run at High Speed. The Cooling
Mode will be maintained until both “Y2” and “Y1” are satisfi ed. As long
as there is still a call for “RH,” the Dehumidifi cation Mode will resume,
and the Supply Fan will run at Low Speed.
If the HB Controller is confi gured for 1 stage of Heating, on a call for
“W1,” the mode changes to Heating. The Economizer will close to its
Minimum Position, Heat Stage 1 will energize, and the Supply Fan will
run at High Speed.
If the HB Controller is confi gured for 2 or 3 stages of Heating, on a call
for “W1,” the Economizer will be locked at its current position, attempting to deliver 55° F Supply Air to the heating section. Heat Stage 1 is
energized, and the Supply Fan will run on High speed. On a call for “W2,”
the HB Controller will enter the Heating Mode. The Economizer will
move to its Minimum Position, and Heat Stage 2 will energize after the
Stage-Up Delay. The Heating Mode will be maintained until both “W2”
and “W1” are satisfi ed. W3 is also available for 3 Stage Electric Heating
Units. As long as there is still a call for “RH,” the Dehumidifi cation Mode
will resume, and the Supply Fan will run at Low Speed.
4
HB Controller Technical Guide
Sequence of Operations
Controller Sequence of Operations
Dehumidifi cation Mode (No Reheat)
Note: If the HB Controller is confi gured for 1 stage of Cooling,
regardless of the Supply Fan confi guration, the Dehumidifi cation call on “RH” is ignored during this mode.
On a call for “RH,” Cooling Stage 1 is energized and the Supply Fan
runs at Low Speed. The Return Air Bypass Damper will open to 100%.
“Y1” is ignored during this mode. On a call for “Y2,” the HB Controller
will enter the Cooling Mode, and the Supply Fan will run at High Speed.
The Cooling Mode will be maintained until both “Y2” and “Y1” are
satisfi ed. As long as there is still a call for “RH,” the Dehumidifi cation
Mode will resume, and the Supply Fan will run at Low Speed.
If the HB Controller is confi gured for 1 stage of Heating, on a call for
“W1,” the mode changes to Heating. Cool Stage 1 will de-energize, the
Return Air Bypass will close, Heat Stage 1 will energize, and the Supply
Fan will run at High Speed.
If the HB Controller is confi gured for 2 or 3 stages of Heating, a “W1”
call will be delayed to extend Dehumidifi cation. On a call for “W2,”
the HB Controller will enter the Heating Mode. Cool Stage 1 will deenergize, the Return Air Bypass will close, Heat Stage 1 will energize,
and the Supply Fan will run at High Speed. Heat Stage 2 will energize
after the Auto Stage-Up Delay. The Heating Mode will be maintained
until both “W2” and “W1” are satisfi ed. W3 is also available for 3Stage Electric Heating Units. As long as there is still a call for “RH,”
the Dehumidifi cation Mode will resume, and the Supply Fan will run
at Low Speed.
2-Stage Cooling with Adjustable Two-Speed or
Two-Speed Supply Fan Control
On a call for “RH,” Cool Stage 1 is energized, and the Supply Fan runs
at low speed. The Return Air Bypass is opened to 100%. The hot-gas
reheat will then modulate the valves to achieve the Supply Air setpoint
DIP switch setting. On a call for “Y1,” the Supply Air setpoint on the
reheat controller is lowered 10° F, and the Return Air Bypass will close.
On a call for “Y2,” the HB Controller will enter the Cooling Mode. The
Supply Fan will switch to high speed, and Cool Stage 2 is energized. The
modulating hot-gas reheat valves will move to the full Cooling position.
The Cooling mode will be maintained until both “Y2” and “Y1” are
satisfi ed. As long as there is still a call for “RH,” the dehumidifi cation
mode will resume.
If the HB Controller is confi gured for 1 stage of heating, on a call for
“W1,” the mode changes to Heating, and the Supply Fan will run at High
Speed. Cool Stage 1 will de-energize, the Return Air Bypass will close,
Heat Stage 1 will energize, and the Supply Fan will run at High Speed.
If the HB Controller is confi gured for 2 or 3 stages of Heating, on a call
for “W1,” the Supply Air Setpoint on the Reheat Controller is raised
10° F, and Cool Stage 1 continues to run. On a call for “W2,” the HB
Controller will enter the Heating Mode. Cool Stage 1 will de-energize,
the Return Air Bypass will close, Heat Stage 1 will energize, and the
Supply Fan will run at High Speed. Heat Stage 2 will energize after the
Auto Stage-Up Delay. The Heating Mode will be maintained until both
“W2” and “W1” are satisfi ed. W3 is also available for 3 Stage Electric
Heating Units. As long as there is still a call for “RH,” the Dehumidifi cation Mode will resume, and the Supply Fan will run at Low Speed.
Lockout Modes
Dehumidifi cation Mode with Hot-Gas
Reheat
1-Stage Cooling with Adjustable Two-Speed
or Two-Speed Supply Fan Control
On a call for “RH,” Cool Stage 1 is energized, and the Supply Fan
runs at High Speed. The Return Air Bypass is opened to 100%. The
Hot Gas Reheat will then modulate the valves to achieve the Supply
Air Setpoint DIP Switch setting. On a call for “Y1,” the HB Controller
enters the Cooling Mode. The Return Air Bypass will close, and the
Hot Gas Reheat will modulate to full Cooling. The Cooling Mode will
be maintained until “Y1” is satisfi ed. As long as there is still a call for
“RH,” the Dehumidifi cation Mode will resume.
If the HB Controller is confi gured for 1 stage of Heating, on a call for
“W1,” the mode changes to Heating, and the Supply Fan will run at
High Speed. Cool Stage 1 will de-energize, the Return Air Bypass will
close, Heat Stage 1 will energize, and the Supply Fan will run at High
Speed. If the HB Controller is confi gured for 2 or 3 Stages of Heating,
on a call for “W1,” the Supply Air Setpoint on the Reheat Controller
is raised 10° F, and Cool Stage 1 continues to run. On a call for “W2,”
the HB Controller will enter the Heating Mode. Cool Stage 1 will deenergize, the Return Air Bypass will close, Heat Stage 1 will energize,
and the Supply Fan will run at High Speed. Heat Stage 2 will energize
after the Auto Stage-Up Delay. The Heating Mode will be maintained
until both “W2” and “W1” are satisfi ed. W3 is also available for 3Stage Electric Heating Units. As long as there is still a call for “RH,”
the Dehumidifi cation Mode will resume.
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 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 or Dehumidifi cation. To reset the lockout
condition, either remove the call for Cooling or Dehumidifi cation or
cycle power to the HB 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.
Economizer and Reheat during Dehumidifi cation modes are locked out
if the SAT sensor is missing.
Note: The Cooling OAT Lockout must be set less than the
Economizer Enable.
HB Controller Technical Guide
5
Sequence of Operations
Controller Sequence of Operations
SAT Lockout Modes
Note: The SAT Lockout Modes only apply if a Supply Air
Temperature Sensor is installed on the HB unit.
SAT High Temperature Limit Cut Off Mode
During the Heating Mode, if the Supply Air Temperature rises above
the Supply Air High Temperature Limit Cut Off (150° F), the Heating
will stage off, but the main Supply Fan will remain on in Low-Speed
operation. If this occurs, the Supply Air Temperature must fall below
80° F in order for the Heating to stage back on. If this condition occurs 2 times consecutively during a Heating call, the HB Controller
will lockout in Supply Air High Temperature Limit Cut Off. To restore
normal operation, either remove the call for Heating or cycle power to
the HB Controller.
SAT Low Temperature Limit Cut Off Mode
During the Heating Mode, if the Supply Air Temperature falls below
the Supply Air Low Temperature Limit Cut Off (40° F), the Outdoor
Air Damper will close. If the Supply Air Temperature is still too cold
and remains there for 15 minutes, the Heating and the Supply Fan will
be turned off and locked out. This condition can only happen once, and
then the HB Controller will lockout in Supply Air Low Temperature
Limit Cut Off. To restore normal operation, either remove the call for
Heating or cycle power to the HB Controller.
Exhaust Fan Control
The Exhaust Fan is energized via the Auxiliary Relay. The Exhaust Fan
has two Economizer Position Activation points based on the Low- and
High-Speed Supply Fan condition. The air balancing contractor should
determine these settings for proper Building Pressure Control.
HB Processor Board
When the HB Controller has the optional HB Processor board installed,
a Space Temperature Sensor can be connected to it for HVAC Mode
Control. When the Space Temperature Sensor is used, the Push-Button
Override and Slide Adjust options are also available. Occupied and
Unoccupied Modes are available through week scheduling, force schedule, and a broadcast schedule. The HB Processor board also provides
communication with other HB controllers. Up to 60 other controllers
can be connected together via the RS-485 loop.
Space Temperature Control Sequence
When the Space Temperature Sensor is confi gured for control, Cooling
and Heating setpoints are used to activate the HVAC Modes of operation.
An HVAC Mode Deadband setpoint is used to determine the temperature
at which the Cooling and Heating Modes are activated above or below the
setpoints. Once in the Cooling Mode, the Space Temperature must drop
below the Cooling setpoint minus the deadband to enter the Vent Mode.
The same is true for the Heating mode; the Space Temperature must rise
above the Heating setpoint plus the deadband to enter the Vent Mode.
An additional Cooling Stage is activated for each 1° F rise of the Space
Temperature above the Cooling Setpoint up to the maximum number of
Cooling Stages available. In like manner, an additional Heating Stage is
activated for each 1° F drop of the Space Temperature below the Heating
Setpoint up to the maximum number of Heating Stages available.
When the Space Temperature rises above the Cooling setpoint plus the
deadband, the HB Controller enters the Cooling Mode, and Cooling Stage
1 is activated. Cooling Stage 2 is activated if the Space Temperature rises
by another 1° F above the Cooling setpoint. Cooling Stage 2 deactivates
when the Space Temperature drops below the Cooling setpoint. Cooling Stage 1 deactivates when the Space Temperature drops below the
Cooling setpoint minus the deadband.
When the Space Temperature drops below the Heating setpoint minus
the deadband, the HB Controller enters the Heating Mode, and Heating
Stage 1 is activated. Heating Stage 2 is activated if the Space Temperature
drops by 1° F. Heating Stage 3 is activated if the Space Temperature
drops by another 1° F below the Heating setpoint. Heating Stage 3 and
Heating Stage 2 both deactivate when the Space Temperature rises
above the Heating setpoint. Heating Stage 1 deactivates when the Space
Temperature rises above the Heating setpoint plus the deadband.
The Slide Adjust feature on the Space Temperature Sensors that are
equipped with this option allows the user to change the Heating and
Cooling setpoints up or down by the Slide Adjust setpoint value. If 3°
F is entered as the Slide Adjust setpoint, when the slider is all the way
up, the Heating and Cooling setpoints will be raised by 3° F. When the
slider is all the way down, the Heating and Cooling setpoints will be
lowered by 3° F. The Override Button feature on Space Temperature
sensors that are equipped with this option allows the user to force the
HB Controller into the Occupied Mode. The time the controller is in
Occupied Mode is determined by the Override Time Setpoint. Once
this time is expired, the HB Controller will follow its normal schedule.
A momentary push of the Override Button will activate the Override.
Once in the Override Mode, pushing down and holding the Override
Button for 5 seconds will deactivate the Override Mode.
6
HB Controller Technical Guide
Installation & Wiring
Controller Installation & Wiring
Controller Mounting
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 controller mounts in the HB unit control panel using the 4 plastic
standoffs located on the HB control enclosure mounting base.
Important Wiring Considerations
Please carefully read and apply the following information when wiring
the HB 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
PIN12 - RAB
PIN13 - CO2
PIN14 - GND
PIN7-24VAC
PIN6 - GND
PIN5 - OAT
PIN4-24VAC
PIN2 - WH PIN3 - RD
PIN1 - BK
HGR VALVE
(SAT) SUPPLY AIR TEMPERATURE SENSOR INPUT
(GND) SUPPLY AIR TEMPERATURE SENSOR INPUT
SEE THERMOSTAT
AND DEHUMIDISTAT
WIRING DIAGRAMS
FOR COMPLETE
WIRING DETAILS
(A1) ECONOMIZER 24 VAC JUMPER
(C1) CLOGGED FILTER SWITCH 24 VAC OUTPUT
(C2) CLOGGED FILTER SWITCH 24 VAC OUTPUT
(A2) ECONOMIZER 24 VAC JUMPER
PIN1-24VAC
ECONO SECTION
P1
HSS CONNECTOR
PIN4 - GN
MHGRV RESET
ECONO POSITION
RETURN AIR BYPASS
GND
PROGRAMMING SOCKET
(R) FROM THERMOSTAT
(C) FROM THERMOSTAT
(RH) FROM DEHUMIDISTAT
(G) FROM THERMOSTAT
(Y1) FROM THERMOSTAT
(Y2) FROM THERMOSTAT
(W1) FROM THERMOSTAT
(W2) FROM THERMOSTAT
(W3) FROM THERMOSTAT
POWER
P10
MHGRV
RESET
ECONO
POS
RAB
GND
LD2LD1
LD3
SAT
GND
R
C
GND
RH
G
Y1
Y2
W1
W2
W3
A1
A2
C1
C2
PIN2 - GND
PIN2 - F-SIGNAL
PIN10 - GND
PIN9 - ECONO POS
PIN8 - CFS
PIN1 - ECONO-24VAC
PIN2 - GND
PIN3 - ECS
HB - MHGR BOARD
ECONOSECTION
P1
P3
ECONO
POS
RAB
EXT
HSS
INT
JO2
JO1
C4
LED2
LED1
R2
R3
C7
SETPOINT
1
TB2
2
C12
U2
4
R27
8
OFF
16
32
R34
64
128
C15
R40
C3
ADD
1
2
4
C19
8
TB1
OFF
16
32
64
C25
128
RESET
C1
LIMIT
PROGRAM
SOCEKT
P1
C27
P5
P5
L1
C30
C29
R66
R67
D23
TB3
V10
R69
POWER
24VAC
GND
C33
P10
PIN3 - GND
PIN1 - GND
PIN7 - COOL-2
PIN8 - COOL-1
PIN9 - LPS
D1
R2
R3
D5
R6
R9
R1
R17
R20
D6
R26
R28
D8
R37
R38
D10
R45
R47
D12
R54
R55
D14
R62
R64
RN3
D15
MOD HGR
C1
R1
C3
R14
R24
R24
HBMHGR
YS101988
RN2
R35
X1
R43
RN1
R52
C26
R59
HB/VBUNIT BOARD
MADEIN THE USA
R68
C6
SERIAL#
C10
REV1
C14
C9 C8
C18
C22
U4
C2
C28
D22
U7
9936
MC34064A
2. All wiring is to be in accordance with local and national
electrical codes and specifi cations.
3. Minimum wire size for 24 VAC thermostat wiring should
be 22 gauge.
4. Minimum wire size for all sensors should be 24 gauge.
5. 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.
6. Be sure all modular wiring harness connectors are seated
fi rmly in their respective modular connectors on the HB
circuit board.
PIN10 - 24 VAC
PIN11 - 24 VAC
PIN12 - GND
PIN6 - HEAT-1
PIN5-24VAC
PIN4 - GND
HB - PROCESSOR BOARD
SW1
V1P9V2
K2
C2
D20
D21
Q9
Q9
Q8
R5
VALVE
HGR
R7
R10
MADEIN THE USA
R12
R16
R15
R19
R18
R21
U5
R22
R23
C9
R25
D7
C12
1
R30
2
R32
4
C4
R36
C35
8
C16
D9
16
L1
32
R41
R42
C34
R44
SW1
D11
R49
D2
R6
C11
R51
RN1
R53
C21
R5
9936
D13
MC34064A
R56
C7
R57
P4
R4
R60
U7
YS101992
REV4
C32
0I
VR2
HBAUXILIARY
R63
PROCESSORBOARD
R65
YS102002
C5
D16
REV2
C10
D1
P2
Q5
Q4
D4
K5
C31
V5
P4
P4
COOLING SECTION
HEAT SECTION
PIN9 - HSM
PIN8 - HEAT-3
PIN7 - HEAT-2
P9
PIN1 - FAN STATUS
PIN2-24VAC
PIN3-24VAC
HEATSECTION
V3
P11
P6
X2
C38
C12
C3
D2Q3D3
P-BUS
P8
HSS
C37
R71
R8
U2
R11
R13
C11
R6
C5
R7
D3
U1
TB1
TMP
ADJ
C17
GND
R39
C39
R8
C20
R9
D4
R3
U6
R2
U5
R58
R61
COMM
C46
R
C2
485DRV
U8
SH
T
R75
R74
C5
R73
HSSDRV
R72
C40
TTL
P3
P2
P7
D1
Q1
D1
PROGRAM
SOCKET
K4
D19
Q7
Q7
C36
C7
SC1
R1
D2
C8
RN1
CLOCK
C8
C9
C10
C14
U2
C13
C11
ADDR
11.059Mhz
C6
R29
C13
SERIAL#
X1
U4
Q10
C43
U1
RN2
EEPROM
C1
X1
C41
C23
C24
C15
U3
C44
C42
U4
C45
R4
C4
R4
U5
LD1
VR1
REC
AUX CPU
Q6
Q2
D18
D17
R31
R33
U3
R70
R46
R48
R50
P-BUS CONNECTOR
PROGRAMMING SOCKET
HSS CONNECTOR
OPTIONAL SPACE
TEMPERATURE SENSOR
TMP
INPUT TERMINALS
ADJ
"ADJ" TERMINAL IS ONLY
GND
USED WITH SENSORS
EQUIPPED WITH THE SLIDE
ADJUST OPTION. CONNECT
"ADJ" TERMINAL ON BOARD TO
"AUX" TERMINAL ON SENSOR
R
SH
T
RS-485 COMM TERMINALS
USED TO CONNECT TO
COMMLINK OR OTHER
CONTROLLERS ON THE
LOCAL COMMUNICATION LOOP
AS REQUIRED
MINI-DIN CONNECTOR
V6V9V7
V8P2V4
SERIAL#
COOLING
SECTION
AUX
PIN1 - E-FAN
P2
PIN2 - GND
AUX
PIN4 - LLT
PIN5 - GND
PIN6 - C-FAN
PIN12 - H-FAN
PIN11 - L-FAN
PIN10 - HPS
Figure 2: HB Controller Wiring (Shown with Optional MHGRV & HB Processor Boards Installed)
HB Controller Technical Guide
7
Installation & Wiring
Controller Installation & Wiring
Single Stage T-stat Wiring For HB Unit
Single Stage T-stat Wiring For HB Units
With 1 Stage Cooling&1StageHeating
With 1 Stage Cooling&1StageHeating
Zone
Zone
Single-Stage Thermostat
(24VAC)
1-Cool / 1-Heat
RC
G
Y1
C
W1
RH
24VAC Power Supply
24VAC to Economizer
Clogged Filter Indicator
(Outputs 24VAC)
24VAC
GND
Note:
The economizer will not have 24VAC to the actuator
without installing a jumper wire between A1 and A2.
If a device needs to disable the economizer, install a
normally closed contact between A1 and A2.
If a device needs to enable the economizer, install a
normally open contact between A1 and A2.
Dehumidistat (24VAC)
Normally Open
DH
DH
HB Controller Terminal Block
TB1
SAT
GND
R
(GND)
C
RH
G
Y1
Y2
W1
W2
W3
A1
A2
C1
C2
TB3
R66
R67
V10
C30
POWER
P10
Figure 3: Single-Stage T-Stat Wiring for HB Unit with 1-Stage Cooling & 1-Stage Heating
8
HB Controller Technical Guide
Installation & Wiring
Controller Installation & Wiring
Single Stage T-stat Wiring For HB Units
With 2 Stage Cooling&2StageHeating
Single-Stage Thermostat
(24VAC)
1-Cool / 1-Heat
RC
G
Y1
C
W1
RH
24VAC Power Supply
24VAC to Economizer
Clogged Filter Indicator
(Outputs 24VAC)
24VAC
GND
Note:
The economizer will not have 24VAC to the actuator
without installing a jumper wire between A1 and A2.
If a device needs to disable the economizer, install a
normally closed contact between A1 and A2.
If a device needs to enable the economizer, install a
normally open contact between A1 and A2.
Dehumidistat (24VAC)
Normally Open
DH
DH
HB Controller Terminal Block
TB1
SAT
GND
R
(GND)
C
RH
G
Y1
Y2
W1
W2
W3
A1
A2
C1
C2
TB3
R66
R67
V10
C30
POWER
P10
Figure 4: Single-Stage T-Stat Wiring for HB Units with 2-Stage Cooling & 2-Stage Heating
HB Controller Technical Guide
9
Installation & Wiring
Controller Installation & Wiring
Single Stage T-stat Wiring For HB Units
With 2 Stage Cooling&3StageHeating
Zone
Zone
Single-Stage Thermostat
(24VAC)
1-Cool / 1-Heat
RC
G
Y1
C
W1
RH
24VAC Power Supply
24VAC to Economizer
Clogged Filter Indicator
(Outputs 24VAC)
24VAC
GND
Note:
The economizer will not have 24VAC to the actuator
without installing a jumper wire between A1 and A2.
If a device needs to disable the economizer, install a
normally closed contact between A1 and A2.
If a device needs to enable the economizer, install a
normally open contact between A1 and A2.
Dehumidistat (24VAC)
Normally Open
DH
DH
HB Controller Terminal Block
TB1
SAT
GND
R
(GND)
C
RH
G
Y1
Y2
W1
W2
W3
A1
A2
C1
C2
TB3
V10
R66
R67
C30
POWER
P10
Figure 5: Single-Stage T-Stat Wiring for HB Units with 2-Stage Cooling & 3-Stage Heating
10
HB Controller Technical Guide
Installation & Wiring
Controller Installation & Wiring
Multi-Stage T-stat Wiring For HB Units
With 2 Stage Cooling&2StageHeating
Multi-Stage Thermostat
(24VAC)
2-Cool / 2-Heat
RC
W2
W1
G
Y1
C
Y2
RH
24VAC Power Supply
24VAC to Economizer
Clogged Filter Indicator
(Outputs 24VAC)
24VAC
GND
Note:
The economizer will not have 24VAC to the actuator
without installing a jumper wire between A1 and A2.
If a device needs to disable the economizer, install a
normally closed contact between A1 and A2.
If a device needs to enable the economizer, install a
normally open contact between A1 and A2.
Dehumidistat (24VAC)
Normally Open
DH
DH
HB Controller Terminal Block
TB1
SAT
GND
R
(GND)
C
RH
G
Y1
Y2
W1
W2
W3
A1
A2
C1
C2
TB3
V10
R66
R67
C30
POWER
P10
Figure 6: Multi-Stage T-Stat Wiring for HB Units with 2-Stage Cooling & 2-Stage Heating
HB Controller Technical Guide
11
Installation & Wiring
Controller Installation & Wiring
Multi-Stage T-stat Wiring For HB Units
With 2 Stage Cooling&3StageHeating
Zone
Zone
Multi-Stage Thermostat
(24VAC)
2-Cool / 3-Heat
W3
W2
W1
Y1
Y2
RC
G
C
RH
24VAC Power Supply
24VAC to Economizer
Clogged Filter Indicator
(Outputs 24VAC)
24VAC
GND
Note:
The economizer will not have 24VAC to the actuator
without installing a jumper wire between A1 and A2.
If a device needs to disable the economizer, install a
normally closed contact between A1 and A2.
If a device needs to enable the economizer, install a
normally open contact between A1 and A2.
Dehumidistat (24VAC)
Normally Open
DH
DH
HB Controller Terminal Block
TB1
SAT
GND
R
(GND)
C
RH
G
Y1
Y2
W1
W2
W3
A1
A2
C1
C2
TB3
R66
R67
V10
C30
POWER
P10
Figure 7: Multi-Stage T-Stat Wiring for HB Units with 2-Stage Cooling & 3-Stage Heating
12
HB Controller Technical Guide
Installation & Wiring
Optional Jumper
Locations
For External Control
Controller Installation & Wiring
Note:
The factory jumpers are located on
the bottom two pins for each 3-pin
header. For field control of either the
Economizer and/or the Return Air
Bypass, move their respective
jumpers to the “External” position on
the jumper pins as shown.
0-10VDC Input Signal for
Modulating Hot-Gas Reheat
2-10VDC Economizer Signal
0-10VDC Return Air Bypass Signal
Common Ground for External Signals
External Control Inputs
MHGRV
RESET
ECONO
POS
RAB
GND
POS
ECONO
JO1
TB2
POS
JO2
RAB
EXTERNAL
INTERNAL
C7
Figure 8: Field Wiring & Jumper Settings for Mod Hot Gas Reheat, Economizer, and Return Air Bypass
HB Controller Technical Guide
13
Programming
Programming with the HB Service Tool
Zone
Zone
Entering Passcodes
The HB Service Tool is used to program setpoints and view the status
of the HB controller. It is connected to the HB controller by means of
a modular cable. The cable is connected between the HB Service Tool
and the HB controller board. The HB Service Tool doesn’t require batteries or a separate power source, because all power to operate the HB
Service Tool is provided through this cable. The HB controller must be
powered in order for the HB Service Tool to function.
Device Address
064
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 fi nished 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.
the DOWN arrow decreases. When the desired letter appears, press the
RIGHT ARROW key to advance to the next letter fi eld. Once all four
letter fi elds spell the desired passcode, press the ENTER key.
Available passcodes are:
● “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.
Enter your passcode as described in the previous section and proceed by
pressing the MENU key. The following screen will be displayed:
Line #2 displays the default address for the HB Controller. If equipped
with a MHGRV Controller, adjust the address to 065 in a similar fashion
as you did when you entered your passcode. Once you have the desired
address on the screen, press the ENTER key. The following screen will
be displayed:
Enter Code
AAAA
The passcode entry screen uses a four-digit alpha passcode. Position
the cursor under the fi rst letter fi eld. To select the desired letter, use the
ADJUST ARROWS. The UP arrow increases through the alphabet and
14
Line #2 displays the controller name or program name. Press the ENTER
key to advance.
Module Selection Screens
After pressing ENTER in the previous step, the fi rst available programming module screen appears. All of the HB controller Status and Setpoint Screens are grouped in specifi c modules designated by a specifi c
function name.
Using the select arrows, scroll to select the desired module on line #1
and press the ENTER key.
HB Controller Technical Guide
Programming
Programming with the HB Service Tool
The other available module screens are listed below in the order that
they would appear as you scroll down.
Factory Options should not be accessed without contacting AAON®
or WattMaster.
Warning: The Factory Options settings should only be ap-
plied when authorized by AAON® or WattMaster
Technical Support personnel. Serious damage to the
controller and/or HVAC unit could result from im proper use of the Factory settings.
OAT Heat Lockout
Line #2 displays “YES” if the Outdoor Air Temperature is above the
Heating Lockout Temperature Setpoint.
OAT Cool Lockout
Line #2 displays “YES” if the Outdoor Air Temperature is below the
Cooling Lockout Temperature Setpoint.
OAT Temperature
Line #2 displays the current Outdoor Air Temperature.
SAT Temperature
HB Controller Status & Setpoints
The Status and Setpoint screens for the various modules are accessed by
selecting a specifi c module and pressing the ENTER key.
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
you to view the Main Status screens for the HB controller. After the
ENTER key is pressed, the following screen will be displayed:
HVAC Mode
Line #2 displays one of the following HVAC Modes:
• Idle • Venting
• Cooling • Econo Cooling
• Heating • Dehumidify
• Econo Dehumidify • Fault
• Force
Press the down SELECT arrow key or up SELECT arrow key to move
forward or backward through the Main Status screens.
Line #2 displays the current Supply Air Temperature.
Alarms
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
Line #2 displays the Month/Day/Year that the HB Controller software
was created.
HB Controller Technical Guide
15
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