Summary of Contents for Mars Comfort-aire Century HBH Series
- Page 1 Installation, Operation & Maintenance Manual Large Belt Drive (HBH/V) Series HBH 072-120 HBV 072-300 60Hz - HFC-410A 517.787.2100 • www.marsdelivers.com • www.heatcontroller.com...
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Page 2: Table Of Contents
Installation, Operation & Maintenance Manual - HBH-HBV Large Table of Contents Model Nomenclature ................................ 3 General Information ................................4 HBH Physical Data ................................6 HBV Physical Data ................................8 Horizontal Installation ..............................12 HBH Field Conversion of Air Discharge.......................... 14 Vertical Installation................................ -
Page 3: Model Nomenclature
Installation, Operation & Maintenance Manual - HBH-HBV Large Model Nomenclature 4 5 6 0 9 6 Supply Air Flow Configuration Model Type S = Straight Supply HB = Heat Controller Compact B = Back Supply F = Front Return T = Top Supply Return Air Flow Configuration Configuration L = Left Return... -
Page 4: General Information
Installation, Operation & Maintenance Manual - HBH-HBV Large Storage Pre-Installation General Information � WARNING! � WARNING! All refrigerant discharged from this unit must Safety be recovered WITHOUT EXCEPTION. Technicians must Warnings, cautions and notices appear throughout this follow industry accepted guidelines and all local, state, and manual. - Page 5 Installation, Operation & Maintenance Manual - HBH-HBV Large Prepare units for installation as follows: � CAUTION! � 1. Compare the electrical data on the unit nameplate CAUTION! All three phase scroll compressors must have with ordering and shipping information to verify that direction of rotation verified at start-up.
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Page 6: Hbh Physical Data
Installation, Operation & Maintenance Manual - HBH-HBV Large HBH Physical Data Model Compressor Quantity Scroll Number of Circuits (Compressors) Factory Charge HFC-410a (oz) [kg] per circuit 60 [1.70] 76 [2.15] 80 [2.27] Blower Motor Blower Motor Quantity Standard Motor (hp) [kW] 1 [0.75] 2 [1.49] 3 [2.24]... - Page 7 Installation, Operation & Maintenance Manual - HBH-HBV Large SS AREA N STRAIGHT DISCHARGE HBH072-120 Dimensional Data ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA DESCRIBED IN NOTES 5 AND 6. RIGHT RETURN STRAIGHT DISCHARGE LEFT RETURN STRAIGHT DISCHARGE Note 6 Note 5, 6 ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA FRONT Note 5, 6...
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Page 8: Hbv Physical Data
Installation, Operation & Maintenance Manual - HBH-HBV Large HBV Physical Data Model Compressor Scroll Number of Circuits (Compressors) Factory Charge HFC-410a - (oz) 60 [1.70] 76 [2.15] 80 [2.27] 112 [3.18] 136 [3.86] 196 [5.56] 224 [6.35] [kg] per circuit Blower Motor Blower Motor Quantity Standard Motor (hp) [kw]... - Page 9 Installation, Operation & Maintenance Manual - HBH-HBV Large HBV072-120 Dimensional Data Discharge Connection Return Air Connections Using Overall Cabinet Water Connections Electric Knockouts Duct Flange Return Air Opening Model Supply Supply Water Water Con- Return Return Depth Width Height Width Depth Inlet Outlet...
- Page 10 Installation, Operation & Maintenance Manual - HBH-HBV Large HBV160-240 Dimensional Data ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA DESCRIBED IN NOTES 7, 8, 9, AND 10. BLOWER ROTATION BLOWER TO AIR COIL RELATIONSHIP FOR TOP DISCHARGE 160-240 (See Note 6) (See Note 5) REAR RETURN TOP DISCHARGE (RR/TD) FRONT RETURN TOP DISCHARGE (FR/TD) NOTES:...
- Page 11 Installation, Operation & Maintenance Manual - HBH-HBV Large HBV300 Dimensional Data ALL CONFIGURATIONS REQUIRE SERVICE ACCESS AREA DESCRIBED IN NOTES 7, 8, 9, AND 10. BLOWER TO AIR COIL RELATIONSHIP FOR TOP DISCHARGE BLOWER ROTATION (See Note 6) (See Note 5) FRONT RETURN TOP DISCHARGE (FR/TD) REAR RETURN TOP DISCHARGE (RR/TD) NOTES:...
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Page 12: Horizontal Installation
Installation, Operation & Maintenance Manual - HBH-HBV Large Horizontal Installation Horizontal Unit Location - Units are not designed Mounting Horizontal Units - Horizontal units have for outdoor installation. Locate the unit in an INDOOR hanger kits pre-installed from the factory as shown area that allows enough space for service person- in Figure 1. - Page 13 4. Electrical access is available on either side (left or right) of the front. included on MARS commercial heat pumps for the purposes 5. Electric box is on right side. It can be field converted to left side. Conversion should only be attempted by qualified...
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Page 14: Hbh Field Conversion Of Air Discharge
Installation, Operation & Maintenance Manual - HBH-HBV Large HBH Field Conversion of Air Discharge Step 3 Remove motor � WARNING! � Step 1 and blower sheav Return air Figure 4: Left Return Side Discharge to Back Front Step 3 WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch Remove motor Step 1... - Page 15 Adjusting bolt - used to raise or lower motor slide assembly. Installation, Operation & Maintenance Manual - HBH-HBV Large Step 4 Remove blower panel Step 4 and access panel Remove blower panel and access panel Move motor clips to Remove 4 other side on bracket motor bolts Move motor clips to...
- Page 16 Installation, Operation & Maintenance Manual - HBH-HBV Large Condensate Piping Duct System Installation Horizontal Installation Figure 5: Right Return Side Discharge to Back Always vent the condensate line when dirt or air can collect in the line or a long horizontal drain line RIGHT RETURN SIDE DISCHARGE is required.
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Page 17: Vertical Installation
Refer MARS will not warrant, or accept responsibility for products which fail, have defects, damage or insuffi- to Figure 7 for an illustration of a typical installation. -
Page 18: Hbv Field Conversion Of Air Discharge
Installation, Operation & Maintenance Manual - HBH-HBV Large HBV Field Conversion of Air Discharge � WARNING! � WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation or conversion. -
Page 19: Hbv072-240 Field Conversion Of Air Discharge
Installation, Operation & Maintenance Manual - HBH-HBV Large HBV072-240 Field Conversion of Air Discharge Figure 8: HBV072 - 120 and HBV160-240 Pictorally Shown Top Discharge Steps to Convert to Straight Discharge Step 1 - For HBV072-120 remote 3 panels. Step 1 - For TCV072-120 remove 3 panels. For HBV160-240 remove 6 panels, middle For TCV160-240 remove 6 panels, middle dividers, and panel mounting brackets. - Page 20 Installation, Operation & Maintenance Manual - HBH-HBV Large HBV072-240 Field Conversion of Air Discharge Upper Mount Holes for Top Discharge Lower Mount Holes for Straight Discharge (2X) Bolts (2X) Bolts Step 2 - Remove motor and then unscrew and remove motor mount assembly. Put motor mount assembly back in lower mount position.
- Page 21 Installation, Operation & Maintenance Manual - HBH-HBV Large HBV072-240 Field Conversion of Air Discharge Step 4 - Rotate blower assembly 90 degrees. Reattach blower assembly to front of unit as Step 3 - Remove (4x) Blower Mount Bolts shown. Put belt on and retighten. Step 5 - Replace panels and misc from step1 (not shown).
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Page 22: Hbv300 Field Conversion Of Air Discharge
Installation, Operation & Maintenance Manual - HBH-HBV Large HBV300 Field Conversion of Air Discharge Figure 8: HBV300 Top Discharge Steps to Convert to Straight Discharge Step 1 - Remove 5 panels, dividers, and panel mount brackets. - Page 23 Installation, Operation & Maintenance Manual - HBH-HBV Large HBV300 Field Conversion of Air Discharge Note: Unlike the 160-240, the TCV300 only has 1 location for the motor mount assembly. Do not remove. Step 2 - Unattach and lift entire 3 blower sub Step 3 - Rotate blower assembly 180 degrees.
- Page 24 Installation, Operation & Maintenance Manual - HBH-HBV Large HBV300 Field Conversion of Air Discharge Step 7 - Replace brackets and 5 panels. Reverse steps to convert straight discharge to top discharge. Step 4 - Attach middle divider. Step 6 - Reattach blower assembly to the front of the unit. Put belt on and retighten.
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Page 25: Hbv Field Conversion Of Control Box
Installation, Operation & Maintenance Manual - HBH-HBV Large HBV Field Conversion of Control Box � WARNING! � Step 1 - Remove control box access panel and panel box will be relocated to. WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation or conversion. -
Page 26: Hbv Field Conversion Of Water Connections
Installation, Operation & Maintenance Manual - HBH-HBV Large HBV Field Conversion of Water Connections � WARNING! � WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation or conversion. -
Page 27: Vertical Condensate Installation
Installation, Operation & Maintenance Manual - HBH-HBV Large Vertical Condensate Installation Condensate Piping - HBV - Remove KO on side that � WARNING! � drain will be connected. Remove access panels. Inside of unit, untie and uncoil drain hose. Form trap in hose, WARNING! Ensure condensate line is pitched toward drain make sure hose is not kinked or deformed. -
Page 28: Piping Installation
Length Optional pressure-rated hose assemblies designed (2 ft [0.6m] Length Standard) specifically for use with MARS units are available. Similar hoses can be obtained from alternate suppliers. Supply and return hoses are fitted with swivel-joint fittings at one end to prevent kinking during installation. -
Page 29: Water-Loop Heat Pump Applications
Installation, Operation & Maintenance Manual - HBH-HBV Large Water-Loop Heat Pump Applications Commercial Water Loop Applications - Commercial piping chips, and other foreign material prior to operation systems typically include a number of units connected (see “Piping System Cleaning and Flushing Procedures” to a common piping system. -
Page 30: Ground-Loop Heat Pump Applications
Installation, Operation & Maintenance Manual - HBH-HBV Large Ground-Loop Heat Pump Applications ˜ CAUTION! ˜ Test vertical U-bends and pond loop assemblies prior to installation. Pressures of at least 100 psi [689 kPa] should be used when testing. Do not exceed the pipe pressure CAUTION! The following instructions represent industry rating. - Page 31 Installation, Operation & Maintenance Manual - HBH-HBV Large HORIZONTAL INSTALLATION Figure 3: Typical Horizontal Unit Installation Figure 13: Typical Ground-Loop Application 3/8" [10mm] threaded rods (by others) Return Air Thermostat Wiring Unit Supply Air Power Flexible Duct Insulated supply duct with Connector at least one 90 deg elbow to reduce air noise...
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Page 32: Ground-Water Heat Pump Applications
Installation, Operation & Maintenance Manual - HBH-HBV Large Ground-Water Heat Pump Applications Open Loop - Ground Water Systems - Typical Water Quality Standards - Table 3 should be open loop piping is shown in Figure 14. Shut off valves consulted for water quality requirements. Scaling should be included for ease of servicing. - Page 33 Installation, Operation & Maintenance Manual - HBH-HBV Large rubber or plastic material that is designed to allow a Flow Regulation - Flow regulation can be specified flow rate. On occasion, flow control devices accomplished by two methods. One method of flow may produce velocity noise that can be reduced by applying some back pressure from the ball valve located regulation involves simply adjusting the ball valve or...
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Page 34: Water Quality Standards
20 mesh] size. The MARS Water Quality Table provides water quality requirements for MARS coaxial heat exchangers. The water should be evaluated by an independent testing facility Rev.: 5/6/2014 S comparing to this Table and when properties are outside of these requirements, an external secondary heat exchanger must be used to isolate the heat pump heat exchanger from the unsuitable water. -
Page 35: Electrical - Line Voltage
Installation, Operation & Maintenance Manual - HBH-HBV Large Electrical - Line Voltage Transformer - All 208/230 voltage units are factory Electrical - Line Voltage - All field installed wiring, including electrical ground, must comply with the National Electrical wired for 208 volt. If supply voltage is 230 volt, Code as well as all applicable local codes. - Page 36 Installation, Operation & Maintenance Manual - HBH-HBV Large Electrical - Line Voltage Table 4b: Compact (HBH/V) Series Electrical Data - (Dual Point Power 60Hz Units) ® Compressor Power Supply Emergency Power Supply Min/ Comp Comp Voltage Blower SCCR kA SCCR SCCR kA SCCR Model #...
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Page 37: Electrical - Power Wiring
Installation, Operation & Maintenance Manual - HBH-HBV Large Electrical - Power Wiring Figure 15 : TCH 072-120 Line Voltage Wiring � WARNING! � WARNING! Disconnect electrical power source to prevent injury or death from electrical shock. � CAUTION! � CAUTION! Use only copper conductors for field installed electrical wiring. -
Page 38: Electrical - Power & Low Voltage Wiring
10°F [-12.2°C] refrigerant temperature, a more suitable temperature when using an antifreeze solution. All diagram for details. MARS units operating with entering water temperatures Low Voltage VA Ratings below 59°F [15°C] must include the optional water/ refrigerant circuit insulation package to prevent internal Components In Unit condensation. - Page 39 120 Valve installed high pressure switch shall have a cut-out pressure of 300 psig and a cut-in pressure of 250 psig. This pressure switch can be ordered from MARS with a 1/4” internal flare connection as part number 39B0005N02. Thermostat...
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Page 40: Electrical - Thermostat Wiring
DXM2.5 control board. Practically any heat pump thermostat back plate against the wall so that it appears thermostat will work with MARS units, provided it has level and so the thermostat wires protrude through the correct number of heating and cooling stages. -
Page 41: Controls - Cxm2 And Dxm2
Installation, Operation & Maintenance Manual - HBH-HBV Large Controls – CXM2 and DXM2.5 CXM2 Controls For detailed controller information, see the CXM2 Application, Operation, and Maintenance (AOM) controller type of your particular unit, refer to digit 9 on the unit model number and the unit nomenclature diagram found on page 3 of this manual. -
Page 42: Blower Adjustment
Installation, Operation & Maintenance Manual - HBH-HBV Large Blower Adjustment Belt Tensioning - An overly loose belt will, upon motor � CAUTION! � start, produce a slippage 'squeel' and cause premature belt failure and or intermittent airflow. An overly tight belt CAUTION! Always disconnect all power supply(s) to unit can cause premature motor or blower bearing failure. -
Page 43: Tensioning V-Belt Drives
Installation, Operation & Maintenance Manual - HBH-HBV Large Tensioning V-Belt Drives General Rules of Tensioning DEFLECTION = BELT SPAN 1. Ideal tension is the lowest tension at which the belt will not slip under peak load conditions. 2. Check tension frequently during the ÿrst 24-48 hours of operation. 3. -
Page 44: Blower Sheave Information
Installation, Operation & Maintenance Manual - HBH-HBV Large Blower Sheave Information Table 4a: HBH/V Blower Sheave and Belt Information Drive Package Configuration Model Component Return/Supply Blower Sheave BK67 X 1" BK85 X 1" BK67 X 1" BK67 X 1" BK67 X 1" Motor Sheave 1VP34 X 7/8"... -
Page 45: Hbh/V 072 Blower Performance
Installation, Operation & Maintenance Manual - HBH-HBV Large HBH/V 072 Blower Performance All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.28 0.32 0.35 0.39 0.42 0.45 0.48 0.52 0.56... -
Page 46: Hbh/V 096 Blower Performance
Installation, Operation & Maintenance Manual - HBH-HBV Large HBH/V 096 Blower Performance All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.45 0.50 0.54 0.59 0.63 0.69 0.74 0.80 0.85... - Page 47 Installation, Operation & Maintenance Manual - HBH-HBV Large Table Continued from Previous Page All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.01 1.08 1.14 1.21 1.28 1.33 1.39 1.45...
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Page 48: Hbh/V 120 Blower Performance
Installation, Operation & Maintenance Manual - HBH-HBV Large HBH/V 120 Blower Performance All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.75 0.81 0.86 0.91 0.97 1.03 1.09 1.15 1.21... - Page 49 Installation, Operation & Maintenance Manual - HBH-HBV Large Table Continued from Previous Page All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.73 1.81 1.90 1.97 2.05 2.12 2.20 2.27...
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Page 50: Blower Performance Data - Hbv160 Standard Unit
Installation, Operation & Maintenance Manual - HBH-HBV Large Blower Performance Data – HBV160 Standard Unit All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.69 0.78 0.86 0.95 1.02 1.11... -
Page 51: Blower Performance Data - Hbv192 Standard Unit
Installation, Operation & Maintenance Manual - HBH-HBV Large Blower Performance Data – HBV192 Standard Unit All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 0.98 1.07 1.16 1.24 1.34 1.47... -
Page 52: Blower Performance Data - Hbv240 Standard Unit
Installation, Operation & Maintenance Manual - HBH-HBV Large Blower Performance Data – HBV240 Standard Unit All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.78 1.89 2.00 2.12 2.24 2.36... - Page 53 Installation, Operation & Maintenance Manual - HBH-HBV Large Blower Performance Data – HBV240 Standard Unit Table Continued from Previous Page All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.78...
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Page 54: Blower Performance Data - Hbv300 Standard Unit
Installation, Operation & Maintenance Manual - HBH-HBV Large Blower Performance Data – HBV300 Standard Unit All Data is Wet Coil SCFM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 2.69 2.84 2.96 3.11 3.27 3.45... -
Page 55: Unit Starting And Operating Conditions
Installation, Operation & Maintenance Manual - HBH-HBV Large Unit Starting and Operating Conditions Table 9a: Operating Limits Operating Limits Environment – Units are designed for indoor installation HBH/HBV Starting Limits only. Never install units in areas subject to freezing or where Cooling Heatin g humidity levels could cause cabinet condensation (such as... -
Page 56: Piping System Cleaning And Flushing
The manufacturer will not be Verify that all strainers are in place (MARS recommends responsible or liable for damages from water leaks due to a strainer with a #20 stainless steel wire mesh). Start the... -
Page 57: Unit Starting And Operating Conditions
Installation, Operation & Maintenance Manual - HBH-HBV Large Unit Starting and Operating Conditions � System water temperature: Check water temperature for proper range and also verify heating and cooling � WARNING! � setpoints for proper operation. � System pH: Check and adjust water pH if necessary to WARNING! Polyolester Oil, commonly known as POE oil, is maintain a level between 6 and 8.5. -
Page 58: Unit Start-Up Procedure
Place the thermostat mode switch in the “HEAT” be between 60°F [16°C] and 95°F [35°C]. position. 5. Two factors determine the operating limits of MARS b. Slowly raise the thermostat to a higher heat pumps, (a) return air temperature, and (b) water temperature until the compressor activates. - Page 59 Installation, Operation & Maintenance Manual - HBH-HBV Large Figure 21: Test Mode Button ⚠ WARNING! ⚠ WARNING! When the disconnect switch is closed, high voltage is present in some areas of the electrical panel. Push test button to enter Test Exercise caution when working with energized equipment.
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Page 60: Unit Operating Conditions
Installation, Operation & Maintenance Manual - HBH-HBV Large Unit Operating Conditions Operating Pressure/Temperature tables in- clude the following notes: • Subcooling is based upon head pressure at • Airflow is at nominal (rated) conditions; compressor service port; • Entering air is based upon 70°F [21°C] DB in heating •... -
Page 61: Start-Up Log Sheet
Installation, Operation & Maintenance Manual - HBH-HBV Large Start-Up Log Sheet Installer: Complete unit and system checkout and follow unit start-up procedures in the IOM. Use this form to record unit information, temperatures and pressures during start-up. Keep this form for future reference. Job Name: Street Address: Model Number:... -
Page 62: Preventive Maintenance
Installation, Operation & Maintenance Manual - HBH-HBV Large Preventive Maintenance Water Coil Maintenance - Condensate Drain - In areas where airborne bacteria (Direct ground water applications only) may produce a “slimy” substance in the drain pan, it may If the system is installed in an area with a known high be necessary to treat the drain pan chemically with an mineral content (125 P.P.M. -
Page 63: Circuit Diagram With Safety Devices
Installation, Operation & Maintenance Manual - HBH-HBV Large Circuit Diagram with Safety Devices SOURCE SOURCE WATER WATER OUTLET INLET SYMBOL LEGEND BALL VALVE BALL VALVE (HOSES TEMPERATURE SENSOR RECOMMENDED) PRESSURE SWITCH REFRIGERANT FLOW COOLING MODE REFRIGERANT FLOW HEATING MODE STRAINER REFRIGERANT FLOW EITHER MODE (OPTIONAL) WATER FLOW... -
Page 64: Functional Troubleshooting
Installation, Operation & Maintenance Manual - HBH-HBV Large Functional Troubleshooting Fault Htg Clg Possible Cause Solution Check line voltage circuit breaker and disconnect. Check for line voltage between L1 and L2 on the contactor. Main power problems Green Status LED Off Check for 24VAC between R and C on CXM2/DXM2.5' Check primary/secondary voltage on transformer. -
Page 65: Performance Troubleshooting
Installation, Operation & Maintenance Manual - HBH-HBV Large Performance Troubleshooting Performance Troubleshooting Htg Clg Possible Cause Solution Dirty filter Replace or clean. Check for dirty air filter and clean or replace. Reduced or no air flow in heating Check fan motor operation and airflow restrictions. Too high of external static. -
Page 66: Functional Troubleshooting Form
Installation, Operation & Maintenance Manual - HBH-HBV Large Functional Troubleshooting Form Water-to-Air Units Model #: l a i f i t & Complaint: REFRIGERANT: HFC-410A HEATING POSITION COOLING POSITION OPERATING MODE: HEATING COOLING REFRIG FLOW - HEATING REFRIG FLOW - COOLING REVERSING CONDENSER (HEATING) VALVE... - Page 67 Installation, Operation & Maintenance Manual - HBH-HBV Large Notes...
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Page 68: Revision Log
Revision History Date: Item: Action: Changed DXM and CXM controls to CXM2 and 1/24/23 DXM2 controls. 02/10/15 Update Air Filter Sizes and Electrical Tables Change Text - Filter “rack” to “frame” 06/13/14 Page 13 & 34 Water Quality table updated 09/30/13 Edit Text - Page 29 Updated...
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