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V3 TROUBLESHOOTING GUIDE FOR HEAT PUMP BOOSTERS MODELS: HPB11, HPB15, & HPB22 PREFACE This guide contains instructions for troubleshooting the Steffes Corporation room heating units: Models HPB 11, HPB 15, and HPB 22. In compiling this guide, Steffes Corporation has used its best judgment based upon information available but disclaims any responsibility or liability for any errors or miscalculations, contained herein, or any revisions, hereof, or which result, whole or in part, from the use of this guide, or any revision hereof. If there are any questions, contact Steffes Corporation technical support at 1-888-STEFFES (783-3337) TABLE OF CONTENTS FLOW CHARTS Unit Will Not Charge (Unit Has No Core Charge) or Control Board Lights Are Off ............................... 1 Unit Undercharges ..................................................................................................................................... 3 Unit Overcharges On Warm Days ............................................................................................................. 4 Cool Discharge Air ...................................................................................................................................... 5 Blower Does Not Run ................................................................................................................................. 6 MISCELLANEOUS Discharge Air Check-Out Procedure .......................................................................................................7-8 Exploded View Diagram of Heat Pump Booster ........................................................................................ 9 Heat Pump Booster Parts List ............................................................................................................ 10-11 Heat Pump Booster Function: Core Charging Problem: Unit will not charge (Unit has no core charge) or Control Board lights are off. Before starting any of the procedures below, check voltage on load side of all HPB circuit breakers and check low voltage fuses on charge control circuit board. Place unit in off-peak mode. Check utility switch and HPB off-peak light on charge control circuit board for proper operation. Check utility switch and HPB off-peak Lights Inoperable Lights Inoperable light on charge control circuit board Lights Operable (51) for proper operation. No Lights Check "Outdoor Temperature Sensor" lights on charge control circuit board. Check "ETS CHARGING" On indicator light on charge control circuitLights board.Operable Off One or more No Check "Outdoor Temperature lights on Lights Off Sensor" lights on charge Jumper thermostat brown lead to control circuit board (51). thermostat orange lead. (NOTE: Check "ETS CHARGING" indicator light on charge control circuit board (51). Charge light on Make sure thermostat shaft is in One or more full clockwise position.) lights on Replace charge control thermostat. Replace charge control circuit board (51). Below 45º refer to the Theory of Operation in Appendix of the Owner's Manual. With charge control circuit board switches in "AUTO" and "WINTER" position: Above 45º Outdoor Temperature fuses Check for 24Both VAC between each of energized the two bottom low voltage fuses and the "C" position (thermostat Check line voltage supply Replace charge control connection), on charge control to control transformer and circuit board. circuit board's terminal block. Voltageunit notwiring. present on one Defective or both Both fuses Ok energized or both Above 45º Outdoor Temperature Repair wiring. Defective Set the charge level selector switch on Below 45º 1. Remove outdoor sensor wire "G". Outdoor the charge control circuit board (51) Replace temperature light #1 should be on. Outdoor to the "HIGH" position and retest. charge control Temperature circuit board. 2. Remove outdoor sensor wire "B". Outdoor temperature light indicator #2 should be on. Okboard switches in With charge control circuit Defective "AUTO" and "WINTER" position: Replace outdoor air temperature sensor. 1. Remove outdoor sensor wire "G". Outdoor circuit board's terminal block. Voltage not Replace thermostat (53). present on one Set the charge level selector switch on Outdoor the charge control circuit board to the Temperature Check outdoor temperature and "HIGH" position and retest. Held Shut temperature light #1 should be on. Check line voltage supply to Replace charge control control Check transformer in-line fuse in(55) and Open circuit board (51). unitsecondary wiring. transformer wiring if equipped. Defective Ok Good Repair wiring. Look for a short circuit in low voltage wiring and replace transformer if necessary. Opens Check slam gate in-line fuse in Check Freely Open assembly behind the Check slam gate transformer secondary Opens units inlet/outlet interlock switch. wiring. Freely ducting ports. 2. Remove outdoor sensor wire "B". Outdoor temperature light indicator #2 should be on. melt links and Replace Replace outdoor air temperature sensor (61). Check for defective Check unit wiring for 24 VAC between each of charge Check sequencers and/or replace the two bottom low voltage fuses (58) or defective charge control and the "C" position (thermostat heating elements (18). on charge circuit board (51). connection), control Charge light on Check outdoor temperature Charge light off and refer to the Theory of Operation. Ok Voltage No Voltage Check for 24 VAC on orange Present On wire going to the top of the Check for defective staging sequencer Check(50). unit wiring charge sequencers or and/or replace defective heating Voltage charge Nocontrol Voltage elements. circuit board. Present Charge light off Jumper thermostat (53) brown lead to thermostat orange lead. Replace control (NOTE: Makecharge sure thermostat circuit board. shaft is in full clockwise position.) Check for 24 VAC between "C" terminal on SFIII board and on orange wire going to the top of the staging sequencer. Good Closed Open Look for shorts in low Check secondary voltage wiring and replace. Adjust or replace. voltage (approximately 24 VAC) Flow chart at the transformer. complete discharge air check-out procedure. Replace charge control circuit board (51). continued on next page. No Voltage Replace Transformer. Page 1 Page 1 Proper voltage present Replace Charge Control Circuit Board. Heat Pump Booster Function: Core Charging Problem: Unit undercharges Before starting any of the procedures below, check voltage on load side of all HPB circuit breakers. Check for 24 VAC between each of the 3-amp low voltage fuses and the "C" position (thermostat connection) on the charge control circuit board's terminal block. Unit undercharges on cold days thermostat Check charge control thermostat knob for proper position. Lessthan than Less Maxusage usage Max Check daily kWh usage. (See daily kWh usage. UnitCheck Specifications in Appendix (See Unit Specifications.) of the Owner's Manual.) Proper Proper Maximum Maximum Usage Usage Ok Unit undercharges on warm days selector switch switch on on the the charge charge Set the charge level selector controlboard board(51) to the position. Check for control to "HIGH" the "HIGH" position. Check properamperage amperagedraw drawon onheating heatingelements elements:(18): for proper slightly) (Thiswill very slightly) systems) HPB11B = 46 AMPS (240V systems) systems) HPB15B = 61 AMPS (240V systems) systems) HPB22B = 92 AMPS (240V systems) Ok LessLess thanthan proper amperage proper amperage Check unit sizing. No Voltage Place the charge control control circuit circuit board switches in in "WINTER" "WINTER" and "AUTO". Disconnect Disconnect outdoor air sensor "W" "W" wire. wire. AllThree Three All Outdoor Outdoor Temperature Temperature Lights On On Lights With the charge charge level level selector selector switch still still in in the the "HIGH" "HIGH" position, check check for for zero zero voltage voltage (49) on charge control resistor from fromthe both the center to bottom both center to bottom and the and center the center to top. to top. Not Not All All Outdoor Outdoor Temperature Temperature Lights Lights On On Check outdoor air temperature sensor sensor in in cold coldplace place(less (lessthan than15 degrees mercury 15 F).F).AllAll mercury bulbs should open. Ok Defective Check VAC on base Check for for 24 24VAC terminals of all all charging charging sequencers (58). sequencers. Voltage Voltage Replace charge control circuit board (51). Replace charge control circuit board (51). Replace charge control circuit board. Replace charge control circuit board (51). All bulbs closed Open Voltage Check for contact closure on all charging charging sequencers (58). sequencers. No Voltage Check unit wiring and/or replace charge control circuit board (51). board. Ok All bulbs open Replace charge control thermostat (53). thermostat. the outdoor temperature Check the outdoor temperature DefectiveCheck Ok lights on charge control circuit lights on charge control circuit board (51). board.All Allthree threemust mustbebeon. on. Replace Replace sequencer (58). sequencer(s). Replace outdoor air temperature sensor (61). temperature sensor. Page 3 Page 2 Check heating elements and(18). replace elements as necessary. Heat Pump Booster Function: Core Charging Problem: Unit overcharges on warm days Before starting any of the procedure below, check voltage on load side of all HPB circuit breaker and check low voltage fuses on charge control circuit board. Lights work Check operation of the three operation of the three "Outdoor Temperature properly Check All lights "ON" regardless of "Outdoor Temperature Lights work properly "ON"temperature regardless of Sensor" lights on charge All lights outdoor Sensor" lights on charge outdoor temperature control circuit board. control circuit board (51). With wires disconnected, check With wires disconnected, check ohm values of the charge control Defective Not ohm values of the charge control Defective Check the charge level selector Not resistor. Must be 175 ohm center Ok Check the charge level selector resistor (49). Must be 175 ohm switch. Unit should not be in Ok Ok to top and center to bottom. switch. Unit should not be in center to top and center to bottom. "HIGH" mode on warm days. "HIGH" mode on warm days. Replace resistor. Ok Ok Ok Replace resistor (49). Fuse bad Check top Set to auto Check unitonwiring and(66) from Defective Check VAC resistor middle to top Setposition. to auto (1Check AMP)topfuse. charge control circuit and middle to bottom. Reults vary depending on (1 AMP) fuse. position. Check outdoor board fuses. number of charging lights on: Fuse bad Fuse Ok sensorCheck wiringoutdoor and Fuse Ok sensor wiring for 1 light on = 24 VAC middle to top and bottom replace the fuse. short to ground and 2 lights on = Ok 0 VAC middle to top;Repair 24 VAC Check for 32 VDC between the "C" position replace the fuse. If middle to bottom Check forconnection) 32 VDC between the "C" control positioncircuit (thermostat on the charge fuse continues to 3 Replace lights oncharge = 0 VAC middle to top and bottom control (thermostat connection) on the charge control circuit board's terminal block and the top low voltage fuse on open, replace charge circuit board (51). board's terminal block and the top low voltage fuse on the charge control circuit board. Incorrect Ok control circuit the charge control circuit board (51). Check fuse. board. Replace charge No voltage present Check unit wiring and Ok No voltage present control thermostat. charge control circuit board fuses. Voltage present Check control Voltage present Replace charge control transformer(s) and the Ok Defective Check control circuit board (51). Ok two lower 3AMP fuses. transformer(s) (55) and the two lower 3AMP fuses. Repair Ok 1. With outdoor air temperature sensor Defective Defective wiring disconnected and the selector switches on the charge control circuit board set to Replace charge "WINTER" and "AUTO" positions, jumper Replace fuse control circuit 1. With outdoor air temperatureoutdoor sensor wiring disconnected and the selector air sensor terminals "W" and "R". The Replace fuse and/or board (51). switches on the charge control circuit set to "WINTER"Sensor and "AUTO" bottomboard Outdoor Temperature light on and/or transformer. positions, jumper outdoor air sensor terminals andboard "R". The bottom charge control"W" circuit should be off. transformer Outdoor Temperature Sensor light on charge control circuit board should be (55). off. 2. Jumper "W", "R", and "B" terminals. The middle and bottom Outdoor Temperature 2. Jumper "W", "R", and "B" terminals. The middle and control bottom circuit Outdoor Sensor lights on charge board Temperature Sensor lights on charge shouldcontrol go off.circuit board should go off. Defective Replace charge control circuit board (51). Defective Ok Ok Replace charge Replace Replace outdoor air outdoor control circuit air temperature temperature sensor(61). board. sensor. Page 4 Page 3 Heat Pump Booster Function: Air Delivery Problem: Cool discharge air Before starting any of the procedure below, check voltage on load side of all HPB circuit breakers. Check for 24 VAC between each of the low voltage fuses the "C" position on the charge control circuit board's terminal block.. Blower delivers cool Cold All Stages discharge air. Blower deliversUncertain cool Cold Stage One Cold All Stages discharge air. Now Warm Still Cold Does the charging system No/Uncertain Iniate emergency work correctly? Refer to heat call. Does the charging system work the Theory of Operation. correctly? Refer to the Theory of Initiate a Stage I heat call. Not Ok Operation in the Appendix of the MakeInitiate sure the duct sensor is positioned Repair a Stage I heat call. No Owner's Manual. properly andduct check field (52) wiring. Not Ok Make sure the sensor is Repair Refer to the appropriate core positioned properly and check field wiring. charging sections: Yes Yes Unit Undercharges Ok Refer to the on appropriate Unit Overcharges Warm Days coreNot charging sections of no Ok Unit Will Charge (Unit has Disconnect the yellow wire this troubleshooting guide. Disconnect the red wire from charge) or Control Board Lights Damper doesn't Damper from the damper the damper motor. motor Initiate(22). a are Off open With duct sensor (52) disconnected doesn't Initiate a heat call, check heat call, check voltage at With interface (21), jumper theat open voltagethe between ductboard sensor disconnected between yellow the wireyellow and 0 VAC red and board, black terminal block wire and the red interface jumper the red and 0 VAC the red wire. wire. positions. Watchblock for damper to open. black terminal positions. Watch for damper to open. 24 VAC24 VAC Damper opens Are the sensors on the duct Damper opens Check voltage between sensor (52) and the air Check voltage between 24 VAC 24 VAC the yellow wire and Replace duct COLD ALL STAGES: Are both of the discharge controller (45) open. the yellow wire and blue wire. sensors on the air discharge controller open? the bluethe wire. Replacesensor duct (52). No sensor. 0 VAC 0 VAC COLD STAGE Yes ONE ONLY: Are both of the sensors on the duct sensor open? Replacethe the interface Replace (21). Replace Replace interfaceboard board. Replace thethe damper Check unit motor appropriate damper motor. (22). No wiring. Yes sensors. Correct Cold Stage One Only Incorrect Correct Check unit Fix wiring. unit wiring. Incorrect Replace the interface board. Page 5 Page 4 Fix unit wiring. Replace the interface Replace air boarddischarge (21). controller or duct sensor. Heat Pump Booster Function: Air Delivery Problem: Blower does not run Before starting any of the procedure below, check voltage on load side of all HPB circuit breakers. Check for 24 VAC between each of the low voltage fuses and the "C" position on the charge controls circuit board's terminal block. Put heater into peak mode. Initiate a peak mode. Initiate a peak mode. Check for 24 VAC across "R" and "C" terminals on booster interface board (21). Check for 24 VAC across "R" and "C" terminals on booster interface board. Voltage present Voltage present Jumper terminal "R" to "W" on the interface board (21). Jumper terminal "R" to "W" on Motor does notboard. run the interface No voltage Replace interface board (21). Replace interface board. Troubleshoot and repair field wiring. Troubleshoot and repair field wiring. Motor runs Check for operation Relay closes of fan relay (54). Check for operation Relay closes of fan relay. Relay will not operate No voltage No voltage Motor runs Motor does not run Relay will not operate Voltage Check voltage at present relay coil. Voltage Check voltage at present relay coil. No voltage Check field wiring and wall thermostat. Check field wiring and wall thermostat. Proper Voltage Check supply voltage to core blower motor (38). Proper Voltage Check supply voltage to core blower motor. Improper Voltage Improper Check unit wiring Voltage and fan limits (44 & 27). Closed Check unit wiring and fan limits. Replace fan relay (54). Replace fan relay. Replace core blower motor (38). Replace core blower motor. Check system wiring. Open Replace fan limit switch(es). Page 6 Page 5 DISCHARGE AIR Check-Out Procedure Models: HPB11B, HPB15B and HPB22B CHECK OUT PROCEDURE: The failure of the melt link is often the result of another problem that exists within the booster. Typically, the failure is a direct result of the inability of the booster to regulate its output temperature. If the primary problem is not rectified, melt link failure could occur again. Thus, after the failed melt link has been replaced, the booster MUST be tested to ensure that failure will not reoccur. 1. Check for proper connection of the remote mounted duct sensor, “IF USED”. CAUTION: Shorting of the duct sensor to the ductwork WILL cause a malfunction in the booster and result in the melt link failing. An inspection of the duct sensor mounting and clearance must be performed. 2. Remove the electrical panel cover on the front of the booster. 3. Disconnect blowers to test damper operation by removing the purple wire from the blower relay. Energize the booster’s control circuit to observe the damper motor. 4. With no heat call to the booster, the damper motor should go to a fully closed (CW) position. (See Figure 1) Figure 1 5. Now, initiate a Stage 2 heat call from the booster’s room thermostat. The damper motor should go to a fully open (CCW) position. (See Figure 2) 6. If the damper does not move to an opened and closed position as shown in Figures 1 and 2, check the damper system for mechanical binding and/or for CCW damper motor malfunction. 7. De-energize the control circuit and remove the “RED” damper motor wire from the CCW terminal. 8. Energize the control circuit again and initiate another heat call from the booster’s CLOSED room thermostat. 9. Check voltage from the COM terminal and the now disconnected “RED” wire Figure 2 on the damper motor. 24 VAC should be present. Also, check the voltage between the COM and CW terminal. No voltage should be present. 10. Remove the air discharge sensor. Inspect the temperature sensing bulbs for separations or breaks in the mercury columns at the center of the bulbs. It may CCW be necessary to warm the bulbs to fully view the mercury columns. In many cases, if a separation exists, it can be removed by the heating of the sensor causing the mercury to move to the top of the bulb. CW CW OPEN CAUTION: Overheating the bulb can cause it to burst. SAFETY GLASSES MUST BE WORN WHEN HEATING THE BULBS. NOTE: Early booster models incorporated an air discharge sensor that signaled the booster’s control system directly. Newer models use triac controls. If the booster that is being serviced does not have the triac switches on the air discharge sensor, it is recommended that the sensor be replaced. 11. De-energize the control circuit. Jumper between the upper and lower copper bulb mounting brackets of the 145 degree mercury bulb (inner bulb) on the air discharge sensor which is located in the base of the booster. 12. Energize the control circuit and check the status of the #4 LED Red light on the booster’s interface board. This light must be energized (indicates the damper is satisfied). 13. Retest the voltage at the damper motor. (Refer to steps 7, 8 and 9.) If the booster does not respond correctly to the voltage check, replace the air discharge sensor. Voltage should be zero between the COM terminal and “RED” damper motor wire. It should also be zero between the COM terminal and the CW terminal. 14. De-energize the control circuit again. With the 145 degree sensing bulb jumper still in place on the air discharge sensor, jumper between the upper and lower copper bulb mounting brackets of the 160 degree sensing bulb (outer bulb). Page 6 Discharge Air Check Out Procedure Continued… 15. Energize the control circuit and check the #4 yellow LED light on the interface board. It should remain on (indicates the damper is satisfied), and there should be 24 VAC between the CW terminal and the COM terminal on the damper motor. 16. If any of the voltage tests performed in this check-out procedure do not yield the correct results, check connections from the booster’s interface board to the air discharge sensor. 17. If all systems check-out, de-energize all circuits and reconnect all wires, remove all jumpers, and reassemble the booster by reversing the disassembly procedure. 18. Restore power to the booster. Consult the factory with questions or if assistance is required with replacing the melt link or checking any the systems described in this procedure. THIS PROCEDURE MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN Page 7 EXPLODED VIEW DIAGRAM Page 8 HPB PARTS LIST NOTE: When ordering replacement parts, please include unit model number and serial number. DWG. REF. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. DESCRIPTION Stainless Steel Panel, Back Stainless Steel Panel, Front Aluminized Steel Panel, Top Aluminized Steel Panel, Right Aluminized Steel Panel, Left 2" Blanket Insulation, Back & Sides (Outer) 2" Blanket Insulation, Back & Sides (Inner) 2" Blanket Insulation, Top & Front (Inner) 2" Blanket Insulation, Top & Front (Middle) 1" Blanket Insulation, Top & Front (Outer) Galvanized Steel Panel, Back Galvanized Steel Panel, Right Galvanized Steel Panel, Left Galvanized Steel Panel, Top Galvanized Steel Panel, Front Element Wiring Harness Core Temperature Sensor Main Wiring Harness Element Jumpers Heating Element (277 V, 1830W) Heating Element (208V, 1830W) Heating Element (240V, 1830W) Heat Storage Brick Control Board Mounting Plate Relay Interface Board (SFIII) Damper Motor Leveling Legs Fan Wiring Harness Base Assembly Core Charging High Limit Switch Assembly 130o F Low Core Temperature Switch Limit Bar Channeling Plate Limit Bar Louvre Panel Painted Panel, Back Painted Panel, Right Painted Panel, Left Painted Panel, Front Painted Panel, Top Electrical Panel Cover Air Delivery Damper Assembly Core Damper Linkage Assembly Core Blower Motor (1/3 HP, 1625 RPM) Page 9 HPB11 ITEM NO. 1140098 1140128 1140085 1140142 1140089 1050050 1050051 1050052 1050053 1050054 1140087 1140087 1140087 1140084 1140086 1040017 1040020 1040016 1040014 1014022R 1014013R 1014014R 1903004 1140140 1023007R 1021003R 1159004 1040013 1141132 1040011R 1040007R HPB15 ITEM NO. 1140099 1140129 1140085 1140141 1140088 1050055 1050056 1050057 1050058 1050059 1140097 1140097 1140097 1140084 1140093 1040019 1040020 1040018 1040015 1014022R 1014013R 1014014R 1903004 1140140 1023007R 1021003R 1159004 1040013 1141132 1040011R 1040007R HPB22 ITEM NO. 1140388 1140380 1140085 1140384 1140392 1050035 1050041 1050047 1040048 1050049 1140396 1190395 1140397 1140084 1140400 1040246 1040020 1040244 1040037 1014022R 1014013R 1014014R 1903004 1140140 1023007R 1021003R 1159004 1040013 1141132 1040011R 1040007R 1140070 1140077 1140100 1140147 1140081 1140090 1140074 1140095 1140111 1141129 1040084 1140070 1140136 1140101 1140148 1140137 1140102 1140074 1140080 1140111 1141129 1040084 1140070 1140136 1140364 1140356 1140376 1140372 1140074 1140080 1140111 1141129 1040084 DWG. REF. NO. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. DESCRIPTION Core Blower Wheel Slam Gate Interlock Switch Slam Gate Melt Link Slam Gate Melt Link Linkage Slam Gate Actuator Complete Air Discharge High Limit Air Discharge Controller Inlet/Outlet Plenum Assembly Motor Run Capacitor Circuit Breaker Standoff Charge Control Resistor Hardboard Base Insulation Charge Control Circuit Board (SFIII) Low Temperature Duct Sensor Charge Control Thermostat Assembly Fan Relay 40VA Control Transformer Electrical Panel Stage 2 Time Delay Sequencer Charging Sequencers 15 Amp Circuit Breaker – GE Brand* 15 Amp Circuit Breaker – Siemens Brand* 60 Amp Circuit Breaker (208/240V) – Siemens Brand* 60 Amp Circuit Breaker (208/240V) – GE Brand* 60 Amp Circuit Breaker (277V) – GE Brand* Outdoor Air Temperature Sensor Assembly 285o Core Temperature Control HPB11 ITEM NO. 1020002R 1024004 1159005 1140236 1141131 1012012R 1040053R 1190004 1018017 1140139 1017027 1050060 1023005 1040054R 1040033R 1018008 1017034 1140072 1019000 1019002 1024012R 1024000R 1024002R 1024013R 1024014 1040032 N/A HPB15 ITEM NO. 1020002R 1024004 1159005 1140236 1141131 1012012R 1040053R 1190004 1018017 1140139 1017027 1050061 1023005 1040054R 1040033R 1018008 1017034 1140072 1019000 1019002 1024012R 1024000R 1024002R 1024013R 1024014 1040032 N/A HPB22 ITEM NO. 1020002R 1024004 1159005 1140236 1141131 1012012R 1040053R 1190004 1018017 1140139 1017027 1050061 1023005 1040054R 1040033R 1018008 1017034 1140072 1019000 1019002 1024012R 1024000R 1024002R 1024013R 1024014 1040032 1040039 * When replacing breakers in a Steffes heating system, it is important to replace with like brand heaters. Page 10