OPERATING MANUAL and INSTALLATION INSTRUCTIONS for
Form HW+3250 rev 7.2
IntelliCon
®
-
HW+
HOT-WATER HEATING SYSTEM ECONOMIZER
For boilers which also supply domestic hot water through an internal coil, plug in a
second sensor to
the ‘Domestic Water Sensor’ connector and mount the sensor on
the domestic hot water outflow-pipe at the storage tank, if present, or at the boiler
domestic water coil outlet-pipe, if no storage tank is used. Follow the same
procedure to attach the sensor as used above for the ‘Heating Water Sensor’. This
sensor should not be used if the boiler does not heat the domestic hot water.
In the event that a sensor fails, the controller automatically goes into bypass mode
and returns full control of the burner to the boiler
’s operating-control, the
‘Power/Normal’ indicator will blink, and the following message will be displayed to
identify the faulty sensor:
“H SENSOR FAULT” and/or “D SENSOR FAULT”, “SYSTEM BYPASSED”
If this message appears check and replace the faulty sensor.
IMPORTANT - READ CAREFULLY
1.
Failure to follow these instructions may result in damage to the
system or cause a hazardous condition.
2.
Installer must be experienced, qualified, and in certain locations,
licensed to work on the system that this control is being installed on.
3.
After installation is complete, follow the check-out procedure as
provided in these instructions to confirm proper system operation.
4.
Intellidyne is not responsible for improper installation or any damages
that may result from improper installation.
5.
Actual wiring may differ from that shown in the diagrams.
6.
Equipment may have controls not shown.
7.
Because the
IntelliCon
can operate with different voltages for the power
and control circuits, it has separate common wires for these circuits. It
is necessary that these wires are connected to the proper commons or
the unit will not function properly.
See the wiring diagrams on the
reverse side of this sheet for details.
IMPROPER VOLTAGE SELECTION MAY DAMAGE THE UNIT AND VOID THE
WARRANTY.
Checkout
Recheck wiring one last time and make sure that the temperature sensor(s) is
plugged into the proper connector(s). The sensor(s) are only detected during
power-up. Set the
controller’s switch to ‘Off/Bypass’ and restore power to the
boiler. Reset the co
ntroller’s switch to ‘On’. After a brief check of the electronics
and displaying various parameters of the controller, the sensor(s) will be detected
and the green ‘Power/Normal’ indicator should light continuously. It is important to
verify recognition of the sensors by viewing the temperature reading(s), on the
display. If the installed sensor(s) are not detected, the IntelliCon controller will not
function properly. If the green indicator is blinking or if the display does not verify
the installed sensor(s), turn the controller
‘Off’ and check the sensor installation.
After the sensor-check, depending upon the temperature of the boiler water at
power-up, the controller will go into one of its various modes. If the controller went
into ‘STANDBY MODE’;
note the operating-control setting
and force a burner
call by temporarily adjusting the operating-control higher and verifying the change
of mode of the controller
to the ‘ECONOMIZER MODE’, ‘HEATING MODE’ or
‘HEATING/LOLIM’ mode. If the controller went in to the ‘ECONOMIZER MODE’ you
can either wait for the water temperature to drop and for the controller to go into
‘HEATING MODE’ or ‘HEATING/LOLIM’, or by removing a sensor plug, the
controller will go into bypass mode, and the burner should fire shortly thereafter. If,
after adjusting the operating-control, the controller went directly into
‘HEATING
MODE
’ or ‘HEATING/LOLIM’ the burner should fire shortly thereafter. The burner
should run continuously until the call from the operating-control is satisfied. Once
satisfied, the burner should stop firing and the controller should go into the
‘STANDBY MODE’. The controller and burner following the above sequence
indicates a properly wired and functioning control.
Make sure that if the
operating-
control was previously adjusted, to return it to its’ previous setting.
If the burner fires for a brief second then stops (even though the operating-control is
calling for the burner to run) is likely caused by the Yellow and Red wires being
reversed. If the controller does not come out of
“STANDBY MODE” when the
boiler’s operating-control is calling for the burner to run, the unit is wired incorrectly.
The likely cause in this situation is either a reversed Yellow and Red wire or an
improperly connected
‘common’ connection for the control circuit. See the
IMPORTANT note (number 7) above.
Service and Troubleshooting
After Installation and Checkout, the controller does not require maintenance and
will provide years of trouble free operation. The unit may be taken out of the circuit
at any time by placing the switch to
the ‘Off/Bypass’ position. In this position, the
unit has no effect on the system and the burner is controlled as it was prior to the
IntelliCon
controller’s installation. This allows service personnel to troubleshoot or
work on the system without the controller intervening.
If at any time the Power/Normal light on the front panel blinks continuously, a
sensor is not operating properly and The
IntelliCon
®
controller has automatically
gone into ‘bypass mode’.
If the message “TIMER FAULT” is displayed the switch should be placed into the
OFF/Bypass position and service called.
If the burner is running and the control is in “STANDBY MODE” a problem exists and
service should be contacted.
PROGRAMMING
The following parameters may be changed in the field by following these instructions.
Pre-Purge time, Temperature indication in either degrees F or C, Heating Water
Low-Limit, Domestic Water Low-Limit, Maximum Economizer Hold-Off Time,
Standby-Timer Override, and whether or not Standby Time, Economizer Time,
Burner Run-Time, and A SAVINGS are Displayed.
The system may also be
returned to factory default values and the Average Savings, Economizer Time, and
Run-Time accumulators may be cleared.
All of the default values have been carefully selected to result in the greatest
savings for the broadest scope of heating system applications. Individual
system requirements may require changes. Please note that all of these
programmable parameters will affect the amount of savings. Prudent changes
are strongly advised.
It is very important that if there is any kind of a delay (more than fifteen (15)
seconds), from the time that the Operating-control calls for the burner to start
and the burner actually starts, that this time delay value be entered into the
controller as a Pre-Purge time (e.g. actual pre-purge timer, Flue Damper
interlock, etc.). If there is a delay and the correct value is not programmed into
the controller, the savings calculations will be incorrect.
ALL PROGRAMMING IS ACHIEVED BY PLUGGING AND UN-PLUGGING A
WATER TEMPERATURE SENSOR INTO THE APPROPRIATE SENSOR-JACK.
THE SENSOR MUST BE CONNECTED TO THE CABLE OR THIS WILL NOT
WORK!
THIS SOFTWARE REVISION HAS A MORE ADVANCED PROGRAMMING
METHOD. THE UPPER (HEATING WATER) SENSOR JACK IS USED TO
ANSWER “YES” OR TO INCREASE A VALUE. THE LOWER (DOMESTIC WATER)
SENSOR JACK IS USED TO ANSWER
“NO” OR TO DECREASE A VALUE. ALL
“YES/NO” QUESTIONS ARE ENDED WITH A “?”. ENTERING A “YES” TO A
QUESTION, WILL CHANGE THE ITEM FROM ITS CURRENT SETTING. TO THAT
WHICH IS SHOWN ON THE SCREEN.
ANSWERING “NO” OR ALLOWING THE 7
SECOND DELAY TO EXPIRE WILL ADVANCE YOU TO THE NEXT SELECTION.
WHEN CHANGING A TIME OR TEMPERATURE VALUE YOU WILL PLUG INTO
THE TOP JACK TO INCREASE THE VALUE OR THE LOWER JACK TO
DECREASE THE VALUE. REMOVE THE SENSOR PLUG WHEN THE DESIRED
VALUE IS REACHED, AND THE VALUE WILL BE SAVED. IF YOU DO NOTHING,
AND ALLOW THE 7 SECOND DELAY TO EXPIRE, THE PROGRAM WILL
ADVANCE YOU TO THE NEXT PROGRAMMABLE PERAMETER.
YOU HAVE SEVEN (7) SECONDS TO RESPOND TO ANY OF THE
DISPLAY PROMPTS.
PROGRAMMING MAY BE STOPPED OR ABORTED AT ANY TIME BY
TURNING THE CONTROLLER OFF. ANY PARAMETERS THAT WERE
CHANGED WILL REMAIN CHANGED.
Entering Configuration Mode:
To enter configuration mode, the controller must be powered up without
any sensors connected. When prompted insert a water sensor plug into the
TOP sensor jack (HEATING WATER). To confirm, remove the plug when
prompted. The unit will then indicated that i
t has entered “**Config
Mode**”. After a 4 second delay the display will advance to the first
programmable parameter.
Any changes made to a programmable parameter will be confirmed
by indicating “ **DATA SAVED**”.
This is a Yes/No type of parameter
This parameter will reset all of the programmable parameters to factory defaults. It will
not clear any of the timer/counter accumulators. Plug into the top jack to perform the
desired function, or plug into the lower jack to answer NO (and proceed to the next
parameter, or allow the 7 second delay to expire and proceed to the next parameter).
This is a Yes/No type of parameter
This parameter will allow you to view all of the time and counter accumulators. Plug
into the top jack to perform the desired function, or plug into the lower jack to answer
NO (and proceed to the next parameter, or allow the 7 second delay to expire and
proceed to the next parameter).
RESET DEFAULTS?
VIEW COUNTERS?
Intellidyne LLC • 5507 Nesconset HWY STE10 PMB148 • Mount Sinai, NY 11766, USA • Email [email protected]
