OPERATING MANUAL and INSTALLATION INSTRUCTIONS for
CHS for b262
IntelliCon
®
-
CHS
(4 - 25 PSI Operating Pressure and 25 - 145 PSI Operating Pressure versions)
COMMERCIAL STEAM HEATING SYSTEM ECONOMIZER
Intellidyne,
LLC
• 303 Sunnyside Blvd., Suite 75 • Plainview, NY 11803 USA • Phone (516) 676-0777 • Fax (516) 676-2640
Description
The Intellidyne IntelliCon
®
-CHS is a patented microprocessor-controlled
fuel-saving device for commercial steam heating systems. The CHS can
be configured for either low pressure (4-25 PSI) or high pressure (25-145
PSI) operation. The CHS is shipped configured for low pressure
applications and requires a low-pressure sensor. High pressure operation
requires a high-pressure sensor and will require the control to be re-
configured. This is accomplished by following the instructions in the
programming section. While working in unison with the boiler’s pressure
controls; IntelliCon
®
-CHS reduces fuel consumption, wear on boiler parts
and burner emissions by dynamically altering the boiler’s response to
heating load changes. This unit is compatible with Intellidyne’s Remote
Display Unit (model RDU) software version 4.3 and higher. In addition,
certain parameters are programmable and are stored in memory that will
not be lost in the event of the unit being turned off or a power failure.
Electric Ratings
Power input: 24,115,220 VAC ± 10%, 5 Watts max., 50/60Hz
Control circuit input: 24,115,220 VAC ± 10%, 0.1A max. Burde
n
Relay Contact: Form B, 10A @ 220 VAC (General Purpose)
Environmental Conditions
For Indoor Use
Maximum Altitude (2000M)
Rated Ambient Temperature 32 -
120˚F. (0 - 49˚C.)
Maximum Rh 90% non-condensing
Mains Supply Voltage Fluctuations ± 10%
Transient Over-Voltage Category (III)
Pollution Degree (2)
Operation
After installation, setting the power switch on the unit to the ‘ON’ position
activates the control. After the system check, the power indicator on the
front of the display will indicate that the power is on. In the event of a
sensor fault the power indicator will blink to indicate a trouble condition.
The four line back-lit LCD display indicates the operational mode of the
device, the measured system pressure/temperatures, total burner run-time
and economizing time, and any warning messages. The possible
messages and their explanation are:
Display Messages - First Line:
‘
STANDBY MODE’ - The boiler’s control has been satisfied and is not
requiring the burner to run.
‘ECONOMIZER MODE’ - The boiler’s control has requested the burner to
come on but IntelliCon
®
-CHS has sensed that there is available heat which
can be used without burning fuel. The burner will remain off and useful
heat will be delivered from the boiler’s existing supply of steam or
condensate.
‘HEATING MODE’ – The burner is running.
‘HEATING LOW LIMIT’ - The unit has switched the burner on due to an
increase in load. This condition may occur occasionally. If this message
appears frequently, the boiler’s pressure control is set too low and should
be increased by 2 PSI (5 PSI for HP version).
During normal operation, the first three messages will appear sequentially.
Display Messages– Second and Third Line :
PSI / KPa. --
HEATING STEAM PRESSURE.
-- The pressure measured
by the pressure sensor is displayed in PSI or KPa.
DOM. --
DOMESTIC WATER TEMP. --
The temperature measured by the
domestic hot water outflow sensor is displayed in degrees F or C.
RTN. --
RETURN WATER TEMP.
-- The temperature measured by the
boiler return water sensor is displayed in degrees F or C.
Note: "N/U" (Not Used), indicates a sensor that was not detected during
power-up.
Display Messages – Fourth Line
BURNER HRS -- The accumulated burner run-time in hours. This value
will reset to zero after 65535.9 hours. This value is stored in non-volatile
memory and will not be lost if the unit is shut-off or if power is removed.
This feature may be shut off via programming.
ECONO HRS -- The accumulated economizing time in hours. This value
will reset to zero after 65535.9 hours. This value is stored in non-volatile
memory and will not be lost if the unit is shut-off or if power is removed.
This feature may be shut off via programming.
In the event that a sensor fails, the power indicator will blink and the unit
will return full control to the boiler’s controls. The display will indicate which
sensor has failed and the RUNTIME will be replaced with the message
"SYSTEM BYPASSED". If a sensor fault message appears; call your
installer for service.
Installation
The CHS unit is electrically wired in series with the boiler’s pressure
control as conceptually shown in the wiring diagram (Fig. 1a or 1b). All
units have multiple voltage inputs for Power and Burner control circuit.
For safety, power to the boiler must be off during installation.
For
improved savings, it is recommended that the burner pressure-control
setpoint should be set so that the minimum pressure at which point the
burner would come on, without The IntelliCon
®
present, is 4 PSI (25 PSI
for HP version). If the setting is higher than that, it should not be re-
adjusted.
Mounting
The control should be mounted using screws in a 3-point mounting
configuration. Screw size should be minimum #8 (4.0mm) - maximum #10
(5.00mm). Length should be suitable for mounting material thickness.
Using the mounting template and suitable hardware, mount the unit
vertically. Consideration should be given to visibility of the display, wiring,
sensor-lead routing, and access to the unit. One mounting point is
centered on the rear of the unit, near the top, and is for the unit to rest/
hang upon. The other two mounting points are accessible through the
wiring compartment, in the lower corners of the enclosure.
Wiring
All wiring and connections must comply with Local and National
Electrical Codes. Connections are made in the wiring compartment
using 1/4" (6.35mm) push-on crimp connectors. The unit should be
wired as shown in the wiring diagram (Fig. 1A or 1B) on the reverse
side.
SENSORS:
(see note # 8 below)
“SUPPLY” (Steam Pressure Sensor)
Attach the pressure sensor to the boiler using standard plumbing practices
for the pressures involved. The pressure sensor must be mounted to a
‘steam pigtail siphon tube’ to protect the sensor from high temperatures
(see fig. 3). Failure to do so will void the sensor warranty. Route the
sensor wire back to the IntelliCon
®
controller in a workman like manner.
Insert the sensor connector into the ‘SUPPLY’ jack (J1) on the unit.
“DOM” (Domestic Hot Water Sensor) ***
For boilers that also supply domestic hot water; attach a temperature
sensor (as shown in fig. 2) to the domestic hot water outflow-pipe at the
storage tank (if used) or at the boiler’s domestic water coil outlet-pipe, if no
storage tank is used, and insulate. Route the sensor wire back to the
IntelliCon
®
controller in a workman like manner and insert the temperature
sensor connector into the ‘Dom’ jack (J2).
This sensor should not be used
if the boiler does not supply domestic hot water.
