Orion HB Mini 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 ................................................................................................................................................................................... 4
Heating Mode ............................................................................................................................................................................ 4
Cooling Mode ............................................................................................................................................................................ 4
Lockout Modes ......................................................................................................................................................................... 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: mail@wattmaster.com
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.
Controller Overview
Technical Guide
General
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.
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
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
C1, C2: Clogged Filter Switch 24 VAC Output Terminals
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
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
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.
4
HB Mini Controller
Controller Installation & Wiring
Technical Guide
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 Mini 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 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
PIN12 - RAB
PIN13 - CO2
PIN14 - GND
PIN7-24VAC
PIN6 - GND
PIN5 - OAT
PIN4-24VAC
HIGH SPEED
SERIAL
COMMUNICATIONS
CONNECTOR
See Thermostat
Wiring Diagrams
For Complete Wiring
Connection Details
(C1) CLOGGED FILTER SWITCH 24 VAC OUTPUT
(C2) CLOGGED FILTER SWITCH 24 VAC OUTPUT
PIN2-24VAC
Figure 2: HB Mini Controller Wiring
ECONO SECTION
P1
P8
(R) FROM THERMOSTAT
(C) FROM THERMOSTAT
(G) FROM THERMOSTAT
(Y1) FROM THERMOSTAT
(Y2) FROM THERMOSTAT
(W1) FROM THERMOSTAT
(W2) FROM THERMOSTAT
(W3) FROM THERMOSTAT
24VAC
GND
P10
HSS
(GND)
PIN1 - GND
PIN10 - HPS
PIN11 - LO_SPD
PIN12 - FAN
PIN6 - COND
PIN5 - GND
PIN4 - LL_TMP
PIN10 - GND
PIN9 - ECONO POS
PIN8 - CFS
PIN1 - SW_24VAC
PIN2 - GND
PIN3 - SPARE IN
ECONO SECTION
P1
HSS
P8
C3
SW1
R71
LD1 LD2 LD3
R27
R34
R40
C1
C12
C15
C19
R
C
C25
G
Y1
Y2
C27
W1
W2
W3
C1
C2
L1
TB3
V10
R66
R67
D23
24VAC
GND
P10
C29
R69
C33
2. All wiring is to be in accordance with local and national
3. Minimum wire size for 24 VAC thermostat wiring should
4. Minimum wire size for all sensors should be 24 gauge.
5. Be sure that all wiring connections are properly inserted
6. Be sure all modular wiring harness connectors are seated
PIN10 - COM_23
PIN11 - COM_23
PIN12 - GND
PIN6 - COM_1
PIN5 - HEAT_1
PIN4 - GND
V1
K2
R12
D20
D21
R10
R1
R2
R3
D5
R24
R26
R28
D8
R35
R37
R38
D10
R43
C18
R45
R47
D12
R52
C22
R54
R55
D14
R59
C28
R62
R64
D15
C30
D22
R68
P4
D19
Q8
Q9
HB MINI
YS102032
REV 1
MADE INTHE USA
SERIAL#
R30
R32
R36
D9
C14
R41
R42
R44
D11
R49
R51
R53
D13
R60
R63
R65
D16
C32
C31
VR2
COOLING SECTION
electrical codes and specifications.
be 22 gauge.
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.
firmly in their respective modular connectors on the HB
Mini circuit board.
V3
Q7
U4
X1
C23
Q4
K5
V5
P4
HEATSECTION
P9
K4
RN1
Q5
D4
V9
COOLING SECTION
HEAT SECTION
P9
P3
P3
HSS
R8
C37
P6
C38
C13
C40
C24
C41
D17
R11
R13
C5
U5
HSS
DRV
U1
C20
U6
C17
C39
R58
R61
VR1
C46
P-BUS
DRV
R4
R75
R72
R73
R74
P-BUS
P11
Q2
Q3
D3
D2
P11
V7
V8
PIN9 - LPS
PIN8 - COOL_1
PIN7 - COOL_2
PIN1 - GND
PIN2 - VFD
PIN3 - GND
PIN9 - HT_MON
PIN8 - HEAT_3
PIN7 - HEAT_2
PIN1 - HEAT_1
PIN2-24VAC
PIN3-24VAC
HIGH SPEED
HSS
SERIAL
COMMUNICATIONS
CONNECTOR
P-BUS
PERIPHERAL BUS
CONNECTOR
HB Mini Controller
5
Technical Guide
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
Single-Stage Thermostat
1-Cool / 1-Heat
W1
Y1
Clogged Filter Indicator
(Outputs 24VAC)
(24VAC)
G
RC
C
RH
HB Mini Controller Terminal Block
(GND)
24VAC
GND
R
C
G
Y1
Y2
W1
W2
W3
C1
C2
TB3
V10
24VAC
P10
Figure 3: Single Stage T-stat Wiring For HB Unit With 1 Stage Cooling & 1 Stage Heating
6
HB Mini Controller
R69
GND
Technical Guide
Single Stage T-stat Wiring For HB Unit
Single Stage T-stat Wiring For HB Units
With 1 Stage Cooling&1StageHeating
With 2 Stage Cooling&2StageHeating
Single-Stage Thermostat
1-Cool / 1-Heat
W1
Y1
Clogged Filter Indicator
(Outputs 24VAC)
(24VAC)
G
C
RC
RH
24VAC
GND
HB Mini Controller Terminal Block
(GND)
R
C
G
Y1
Y2
W1
W2
W3
C1
C2
TB3
V10
24VAC
P10
Figure 4: Single Stage T-stat Wiring For HB Units With 2 Stage Cooling & 2 Stage Heating
HB Mini Controller
R69
GND
7
Technical Guide
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 2 Stage Cooling&3StageHeating
Single-Stage Thermostat
1-Cool / 1-Heat
W1
Y1
Clogged Filter Indicator
(Outputs 24VAC)
(24VAC)
G
C
RC
RH
24VAC
GND
HB Mini Controller Terminal Block
(GND)
R
C
G
Y1
Y2
W1
W2
W3
C1
C2
TB3
V10
24VAC
P10
Figure 5: Single Stage T-stat Wiring For HB Units With 2 Stage Cooling & 3 Stage Heating
8
HB Mini Controller
R69
GND
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