OPERATING MANUAL and INSTALLATION INSTRUCTIONS for
Form HW+3250 rev 7.2
IntelliCon
®
-
HW+
HOT-WATER HEATING SYSTEM ECONOMIZER
Description
The
IntelliCon
®
-HW+
is a patented microprocessor-based fuel-saving
controller for hydronic heating systems up to 300M BTUs. It reduces fuel
consumption, wear on boiler parts and burner emissions by actively
managing the burner, in conjunction with the boiler operating-control, to
properly match the boiler output to the required load. This controller
indicates actual savings on a burner cycle by cycle basis and also
indicates the averages of these cycles. This unit is compatible with
Intellidyne’s Remote Display Unit (model RDU). In addition, certain
parameters are programmable. All of the programmable parameters and
savings values 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. Burden
Relay Contact: Form B, 10A @ 220 VAC (General Purpose)
Environmental Conditions
For Indoor Use.
Maximum Altitude: 6500 Ft. (2000M)
Rated Ambient Temperature: -
20˚ -- 120˚F. (-29˚ -- 49˚C.)
Maximum Rh: 80% non-condensing
Mains Supply Voltage Fluctuations: ± 10%
Transient Over-Voltage Category: (III)
Pollution Degree: (2)
Note: The IntelliCon control must be operated within the specifications and
protected from the elements. Failure to do so voids the warranty and
guarantee. Below 32˚F (0˚C), the control will continue to operate but the LCD
display may not function properly. The display will return to normal above
that temperature.
Operation
After installation, setting the switch on the controller
to the ‘ON’ position
activates the control. The LCD display
indicates the various ‘modes’
of
the device, sensed temperatures, and percent savings. The possible
messages and their explanation are:
The boiler is operating under its own internal operating-control, which
has turned the burner off. This occurs for a period of time after the burner
has shut down.
The boiler operating-control has requested the burner to come on but the
controller 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 residual heat.
The controller has released the burner to fire.
The controller has released the burner to fire due to a load condition that
has caused the water temperature to go below the programmed low
limits. This condition may occur occasionally. If this message appears
frequently, the boiler operating-control may need to be increased in 5ºF
(3ºC) increments until the condition stops or the
“low limits” may need to
be adjusted (see Programming section)
During normal operation, one of the above messages will be
alternated with the message(s) below.
The measured value of the boiler outflow water temperature is displayed
in
˚F (may be programmed for ˚C).
The measured value of the domestic hot water outflow temperature is
displayed in
˚F (may be programmed for ˚C). This message will only
appear if the boiler supplies domestic hot water and the optional second
sensor is installed (see Sensor Section of these instructions).
The calculated average savings of all burner cycles since commissioning of
the controller. The option to display this screen is programmable (Default
= ON).
Note: The numeric value will not be displayed until a value that
is greater than zero is calculated.
Total hours of Standby time. (maximum = 99,999.9 hours).
Total hours of Economizer time. (maximum = 99,999.9 hours). The option
to display this screen is programmable (Default = ON).
Total hours of Burner run-time. (maximum = 99,999.9 hours). The option
to display this screen is programmable (Default = ON).
Installation
The controller is electrically installed in series
(NEVER IN PARALLEL)
with the boiler operating-control as shown in the wiring diagrams on the
back page of these instructions. It is very important that it be installed,
electrically, before any interlocks to ensure proper operation of the burner
and to eliminate any alarm or fault conditions that could be caused by the
IntelliCon controller holding the burner off.
AT NO TIME SHOULD ANY
SAFETY CONTROLS OR CIRCUITS BE CIRCUMVENTED.
Check and
determine the voltages of the burner control circuit and power circuit prior
to installation.
To ensure maximum savings and proper operation, the following
recommended settings should be made:
For Single Aquastats
– HLOLIM should be set 15
˚
F (9˚C) below the
aquastat setpoint minus the differential setting. (e.g. for an aquastat with a
setpoint of 170˚F, with a 10˚F differential the HLOLIM setting should be:
170˚-10˚-15˚=145˚). The DLOLIM should be set to the minimum desired
temperature of the Domestic Hot-Water (if Domestic sensor is used).
For Dual or Triple Aquastats: The HLOLIM parameter should be set 5˚F
(3˚C) below the setting of the “B” stat. The DLOLIM parameter should be
set 20˚F (12˚C) below the setting of the “B” stat.
These values can be seen during power-up and are programmable.
Positioning
The unit may be mounted on the equipment either vertically or horizontally.
For readability of the display, the vertical position is preferred. The unit
should be mounted directly on the existing electric enclosure via the unit’s
standard ½” electrical fitting or surface mounted using the accessory
mounting bracket.
Wiring
All wiring and connections must comply with Local and National
Electrical Codes. The unit should be wired as shown in the wiring
diagrams on the reverse side. It is important to read all of the
instructions and the NOTE on the other side of these instructions.
Ensure that POWER TO THE UNIT IS OFF DURING INSTALLATION
and that all unused leads are individually taped/insulated.
Sensors
Insert the sensor wire plug
into the ‘Heating Water Sensor’ connector
located on the side of the unit. Mount the sensor on the boiler outflow pipe
using tie-wraps (see Fig. 2) or other secure method as close to the boiler
as possible. Make sure that the sensor makes good thermal contact with
the pipe. Cover the sensor with a small piece of pipe insulation (not
provided) and secure in place (see Fig. 3).
S T A N D B Y M O D E
ECONOMIZER MODE
H E A T I N G M O D E
HEATING / LO LIM
HEAT TEMP = xxx˚F
DOM TEMP = xxx˚F
A S A V E = x x . x %
ST HRS = xxxxx. x
ET HRS = xxxxx. x
RT HRS = xxxxx. x
Intellidyne LLC • 5507 Nesconset HWY STE10 PMB148 • Mount Sinai, NY 11766, USA • Email [email protected]
