HIRED-HAND ICS-500 User manual

4801-0102 REV 9/96
ICSICS--500 Environmental Controller500 Environmental Controller
With Back-up system and Contactor Panel
Hired Hand, Inc.
1733 Co Rd 68
PO Box 99
Bremen, AL 35033

Integrated Control System 500 Table of Contents
Integrated Control System -500
Table of Contents
1. Purpose ___________________________________________________________________________1
2. Ratings/Specifications________________________________________________________________1
3. Warnings __________________________________________________________________________1
4. Warranty __________________________________________________________________________2
5. Installation_________________________________________________________________________2
5.1. Tools Required ____________________________________________________________2
5.2. Instructions_______________________________________________________________2
6. Components Description______________________________________________________________3
6.1. Controller ________________________________________________________________3
6.1.1. General Description _____________________________________________________________3
6.1.2. Controls ______________________________________________________________________4
6.1.3. Wiring Connections____________________________________________________________10
6.2. Back-up System __________________________________________________________14
6.2.1. General Description ____________________________________________________________14
6.2.2. Controls _____________________________________________________________________14
6.3. Contactor Panel __________________________________________________________17
6.3.1. General Description ____________________________________________________________17
6.3.2. Terminal Locations/Types _______________________________________________________17
6.3.3. Controls _____________________________________________________________________17
7. Operation_________________________________________________________________________18
7.1. Curtain Operation ________________________________________________________18
7.1.1. Standard _____________________________________________________________________18
7.1.2. Tunnel (Enhanced Version Only) _________________________________________________18
7.2. Stage Operation __________________________________________________________19
7.2.1. Manual ______________________________________________________________________19
7.2.2. Automatic____________________________________________________________________19
7.3. Back-up Operation________________________________________________________20
8. Maintenance ______________________________________________________________________20
9. Wiring Diagrams___________________________________________________________________20
10. Troubleshooting___________________________________________________________________24
10.1. Curtain machine does not operate Manually._________________________________________24
10.2. Curtain machine does not operate Automatically______________________________________24
10.3. Temperature Sensors not reading correctly __________________________________________24
10.4. A Stage not working correctly ____________________________________________________24
10.5. If Stages are not working at all____________________________________________________25
10.6. If Backup System is not working at all______________________________________________25
10.7. If Variable Speed unit is not working at all __________________________________________25
11. Exploded View/Parts List ___________________________________________________________28
12. Programs ________________________________________________________________________32

Integrated Control System 500 1
Integrated Control System -500
1. Purpose
The Integrated Control System model 500 (ICS-500) is an eight stage temperature controller intended for
use in agricultural enclosures. The ICS-500 incorporates an electronic temperature controller, an eight
stage contactor panel, and an independent back-up system.
2. Ratings/Specifications
•120 or 240 volts / 6 Amps Maximum / 50/60 hertz (depending on model purchased).
•2 hp maximum per stage.
•8 stages of heating or cooling plus integrated curtain machine operation.
•8 Amp variable speed fan circuit available.
3. Warnings
Warning!
When this system is used in a life support heating and ventilation system
where failure could result in loss or injury, the user should provide
adequate back-up, or accept the risk of such loss or injury.
Warning!
Wiring and connections must comply with all national and local electrical
codes. Installation by qualified electrician required.
Warning!
Electrical shock may occur if the panel is opened with power connected to
the unit. Before opening the enclosure, make sure that all power sources
to panel, and each stage, are disconnected.
Warning!
The individual stage toggle switches’ “OFF” position will not prevent the
stage from turning on if the back-up system control board senses
temperature above the high limit or below the low limit. For this reason,
the “off” position is not an acceptable electrical isolation for equipment
connected to that stage.

Integrated Control System 500 2
4. Warranty
One Year Limited Warranty
The ICS-500 is warranted for one year from date of purchase against electrical
and mechanical defects in material and workmanship. If this unit fails to operate
during this period, return it, prepaid to the address below, for repair or
replacement without charge, at the manufacturer's option. Damage by accident
or abuse is not covered by this warranty. This warranty gives you specific rights
which vary from state to state. For claims on this warranty, contact your dealer.
Warrantor: Hired Hand, 1733 Co Rd 68, Bremen, AL 35033.
5. Installation
5.1. Tools Required
Drill Screwdriver
Crimping Pliers Kit Bag (Included)
5.2. Instructions
1. Unpack system, and check that all components are present.
2. Insert two screws into wall approximately 18” apart, leaving the heads away from
the wall.
3. Hang ICS-500 over the two screws. The top two holes in the side flanges are slotted
to allow easy hanging.
4. Finish mounting the unit by securing the sides with eight more screws
5. Make sure all power supplies are disconnected before breaking any wires, or
reaching into the panel.
6. Open ICS-500 panel, and find all connections.
7. Run sensors out to locations inside the house. (One sensor outside the house with
OSC model.) Be sure that the sensors are in a safe location, free from any
temperature influences (direct sunlight, water, etc.)
8. Connect each sensor to its appropriate terminals inside the ICS panel. (See wiring
diagrams in the back of this manual.)
9. Connect wires from staged equipment to the appropriate stage. Be sure to align the
heat/cool switches to the appropriate settings. See wiring diagrams for locations of
terminals.
10. Hookup three wire connection from System 500 board to PVR-H. See wiring
diagrams for locations of terminals.

Integrated Control System 500 3
CONTROLLER
System 500
POWER CURTAINPOWER CURTAIN
Automatic
mode...
!
!
Back-Up
System
Manual Stage
Controls
System 500
Power Curtain
Controller
The ICS-500 Environmental Controller.
6. Components Description
6.1. Controller
6.1.1. General Description
The System 500 Power Curtain controller is an electronic environmental controller
which uses knobs for user controls. The controller can operate the following:
ðOne curtain machine intelligently based on time.
ðEight stages of heat and cool.
ðUser selected 5 or 10 minute timer.
ðAny stage can be on either a stir timer, or a negative timer.
ðTwo temperature sensors for inside the building. (One extra for
outside temperature with OSC model.)
In addition to the basic operation outlined above, an enhanced model is available which
includes the following functions:
ðVariable speed fan.
ðTunnel ventilation control.
ðOpen/Close operation of a tunnel inlet curtain.

Integrated Control System 500 4
6.1.2. Controls
6.1.2.1. Front Panel
The following controls are located on the outside of the panel.
6.1.2.1.1.Automatic/Manual
The automatic/manual switch is used as its name implies. The
Automatic position allows the controller to move the curtains to
control temperature. When the switch is in the manual position, the
controller will still operate the stages to control temperature, but the
curtain can only be moved using the open/close/off switch.
6.1.2.1.2.Open/ Close/Off
The open close off switch is used for manual control of the curtains.
This switch is only operable when the automatic/manual switch is in
the manual position. At other times, this switch is not operable, thus
its position is not significant. However, it is a good practice to always
leave the switch in the off position.
The “OPEN” position of the switch allows current to flow to the PVR-
H, allowing power to the “open” windings of the curtain machine. The
“CLOSE” position of the switch allows current to flow to the PVR-H,
allowing power to the “close” windings of the curtain machine. The
“OFF” position does not allow current to the PVR-H, but is not a safe
electrical disconnect for the curtain machine.

Integrated Control System 500 5
6.1.2.1.3.Alternate Program Switch
PROGRAM
(Programa)
A
B
Each of the 256 stage programs has another “shadow” program. This
separate program is provided to make the change between brooding
and full house operation. Position A is a program tailored for
brooding, whereas program B is for full house operation.
6.1.2.1.4.Target Temperature
TARGET TEMPERATURE
(Temperatura Optima)
INCREASEDECREASE
(Disminuir) (Aumentar)
The target temperature knob is used for the adjustment of target
temperature. This setting is very important, because all system
operations other than the timer are operated by the distance between
target temperature and actual temperature. At all times, the system
will try to maintain target temperature.
6.1.2.1.5.Timer Percentage
TIMER PERCENTAGE
(Reloj De Ventilacion Minima)
TIMER
INCREASEDECREASE
(Disminuir) (Aumentar)
This control allows the operator to specify the amount of time a stage
on the timer stays energized. For example:
10 Minute timer with Timer Percentage at 40%
The stage will be active for 40% of 10 min.--4 min.
The timer percentage control works in the same manner for a 5 minute
timer.
On this display, the word "Timer" will be backlit red if the stages on
the timer are active.

Integrated Control System 500 6
6.1.2.1.6.OSC High Limit (Enhanced Version Only)
OUTSIDE SENSOR CONTROL
OSC
INCREASEDECREASE
(Disminuir) (Aumentar)
The Outside Sensor Control (OSC) High Limit knob allows the user to
set the temperature for the controller to go into tunnel mode. Tunnel
mode involves shutting the main curtain, opening the tunnel curtain,
and staging in tunnel fans. When temperature on the outside of the
house reaches the OSC High Limit, the controller will automatically
switch to tunnel control.
On this display, the letters "OSC" will be backlit red if the controller
has switched to tunnel mode.
6.1.2.2. Inside
To see the other controls on the System 500 Power Curtain controller, you will
need to open the panel door. These controls will be located on the large green
circuit board attached to the door of the panel.
6.1.2.2.1.Program Bank and Stages
Stages
Prog Bank
A
B
C
D
E
F
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
0
1
2
3
4
5
6
7
8
9
To change stage programming, use a
small screwdriver to select one of the
sixteen positions on the "stages" switch.
Each letter or number corresponds to a
different stage setup. These programs
are shown in the back of this manual.
The two switches shown above work together to tell the controller
which stage program to use. Each switch has sixteen positions; 0
through 9, and A through F.
To change programs, you will need to look at the program list at the
back of this manual. Look at the program name (1,0; 2,3; A,5; etc.)
The first number or letter is the program bank position; the second is
the stages position. To select that particular program, use a
screwdriver to align each of the two rotary switches to the
corresponding positions.
The system comes programmed with up to 256 stage programs. These
programs are listed in the back of this manual. Remember "Do not
change stage programs with power applied to the controller."
Disconnect power before opening controller box for any reason.

Integrated Control System 500 7
6.1.2.2.2.Stage On Timer Jumpers
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Stage 7
Stage 8
Jumper pins A and B for STR Timer Jumper pins B and C for NEG Timer
To place a stage on the Timer
install a two pin mini-jumper
on the pins adjacent to the
appropriate stage
ABC
This controller allows you to put any or all stages on the timer. Install
a jumper on the two pins beside the appropriate stage. This block is
found close to the center of the board.
6.1.2.2.2.1.Negative Timers
A negative timer is a timer which will operate whenever the curtains
are closed, and the house is being ventilated using negative
ventilation. A stage set on a negative timer will not be timed when the
curtains are open. To place a stage on negative timer, push a two-pin
jumper on pins B & C next to the stage you wish to use. Stage six
above is shown as a negative timer.
6.1.2.2.2.2.Stir Timers
A stage on a stir timer may operate at any time, regardless of curtain
position. To place a stage on stir timer, push a two-pin jumper on pins
A & B next to the stage you wish to use. Stage 3 above is shown as a
stir timer.
6.1.2.2.3.Single/Double Inside Sensor Jumper
Use Pins A-B for Double Inside Sensor
Use Pins B-C for Single Inside Sensor
This feature allows you to operate the controller with only one working
sensor attached.
This is not highly recommended due to temperature differences which
exist throughout any enclosure. These differences can be due to drafts,
dead air spots, etc. Use the single inside sensor option only if one
sensor has been damaged, and only until you have purchased a new
sensor for replacement.
Under normal operating conditions you should use two inside sensors,
as the controller will have a better understanding of actual house
temperature.
Warning: If you do not have a jumper installed on this set of
pins, the controller will not function properly, and your house
will have to depend upon the back-up.

Integrated Control System 500 8
6.1.2.2.4.Five/Ten Minute Timer
INSTALL JUMPER FOR
5 MINUTE TIMER
The controller's internal timer is normally a ten minute timer.
However, installing a jumper on this position allows you to set the
internal timer to a five minute timer.
6.1.2.2.5.Run Time Adjust
This setting tells the controller how long to run the curtain machine
when a change is needed. If 60 seconds is selected, the controller will
run the machine for 60 seconds, or until the curtain is fully open, or
closed.
6.1.2.2.6.Cycle Time Adjust
This potentiometer is used to set the time delay between curtain
operations. If cycle time is set for 3 minutes, then the curtain will
move every 3 minutes if needed. The curtain will not move between
cycles, unless it is manually moved.

Integrated Control System 500 9
6.1.2.2.7.Variable Speed Fan (Enhanced Version Only)
6.1.2.2.7.1.Variable Minimum Adjust
If you have the enhanced version of this controller, this
potentiometer controls the minimum speed of the variable
speed fan. For example, if the variable minimum is set at
50%, the fan will never run below half speed.
If you have the basic version of the controller, these switches
are not installed.
6.1.2.2.7.2.Variable Span Adjust
This setting controls the temperature difference between the
minimum speed temperature setpoint and the maximum
speed setpoint. In other words, this value represents the range
of the variable speed fan.
6.1.2.2.7.3.Variable Offset Adjust
The variable offset is the number of degrees from target
temperature at which the variable speed fan will be at
minimum speed. For example, if target temperature is 75
degrees, and the variable offset is set at minus 5 degrees, then

Integrated Control System 500 10
the fan will be running at minimum speed when temperature
equals 70 degrees.
Example:
Minimum 40 percent
Offset 5 degrees
Span 10 degrees
Target Temp 75 degrees
The variable speed fan will run at 40% when the inside temp
is 70 degrees (target -offset). The controller will increase fan
speed if inside temperature is rising up until 80 degrees
[(target -offset) + span] at which point the fan would be
running at 100 percent.
6.1.3. Wiring Connections
The following pages show the wiring connections from the System 500 board.

Integrated Control System 500 11

Integrated Control System 500 12

Integrated Control System 500 13

Integrated Control System 500 14
Black White White Black Red AC Supply Control Circuit
White
Yellow
Orange
Red
Brown
Blue
Black
Green
White
Yellow
Orange
Red
Brown
Blue
Black
Green
Red
Black
White
White
Black
AC SupplyControl Circuit
9 Conductor from PowerTrak
Purple
Green
Cap off Purple & Green
with wire nut.
Connection of Curtain Control Circuit and PowerTrak to PVR-H.
6.2. Back-up System
The back-up system included with the ICS-is exactly the same unit that comes standard with our
Contactor Control System (CCS™). This unit works independent of the controller, and can
activate any of the stages.
6.2.1. General Description
The back-up system has its own sensor which allows the board to continuously monitor
house temperature separately from the controller. If this temperature should exceed the
limits set by the controller, the back-up system would engage the appropriate equipment.
(For example: If the temperature is below the low limit setpoint, the back-up board
would engage all heat stages.)
Note: If power to the back-up board is lost, all stages will turn on.
The back-up board allows for a two step cool stage engagement. For a description of the
two step cool stage option, see section 6.2.3.2 below. If you want to use the two step
option, you will need to change the wiring inside the panel. For a diagram, see the
drawing on the next page.
6.2.2. Controls
The back-up system has three controls: Two temperature limit knobs, and a reminder
reset button. The temperature knobs are labeled “High Limit” and “Low Limit”.
6.2.2.1. High Limit
If for some reason (lightning, voltage fluctuations, etc.) your controller should
quit functioning, or function improperly, the back-up system in your CCS panel
would take over if temperature exceeded the limits. If the temperature felt by

Integrated Control System 500 15
the sensor reaches one degree above the high limit, the back-up board would
start all stages set to cool one. (This could be any, or all of your cool stages.) If
temperature continues to rise, the back-up would then start cool 2 (all other
cool stages). This should lower temperature below the setpoint.
If you use the unit as shipped, the back-up system would engage all cool stages
at the same time.
Note: If you want the two step cooling option, you will need to wire the panel as
shown in the drawing on the next page.
6.2.2.2. Low Limit
If your house temperature drops below the low limit, all heat stages would be
turned on by the back-up board until temperature is brought back up to the low
limit.
6.2.2.3. Reminder Reset Button
The last control on the back-up board is the reminder reset button. During a
growout you lower house temperature as your animals mature. It is vitally
important to reset your high and low limits as well. If you did not reset your
back-ups, the difference between target temperature and the back-up setpoint
could reach 30 to 40 degrees. The reminder alert buzzer warns you to check
your back-up setpoints every five days. Note: It is important to check your
back-up setpoints daily.
Z2
Z1
RLY1
RLY2
RLY3
BP1
uln2803n
pic16c71xt
X1
C4
C5
U2U1
R20
R19
R18
R8
R7
Q2
R9
R10
Q1
R17
R16
R15
R14
R11
R12
R13
R6
R5
R4
R3
C3
VR2
C2C1
HIRED-HAND R
-
+
ALARM
VR1
J3
ZNR1 ZNR2 BR1
J5 J9J8J7
AC SENSOR
+
-
J2J1 J4 J6
COOL 2 COOL 1 HEAT
J11 J10
PCB131 (Rev B) 19 July 1994 M. Calvert c 1994,1995 Hired Hand, Inc.
P/N 3580-0131
Z4
Z3
White
Shield Black
The White and Shield wires need
to be crimped together and
connected to this terminal.
Connecting Sensor to
Back-Up Board

Integrated Control System 500 16

Integrated Control System 500 17
6.3. Contactor Panel
6.3.1. General Description
Hired Hand’s Contactor Control System is a pre-wired set of heavy contactors designed
to allow automatic switching of large loads. (Up to 2 Hp per stage.)
6.3.2. Terminal Locations/Types
Along the left hand side on the inside of the contactor panel are two long terminal
strips, each section of strip is labeled with stage number, line in, and line out. Be sure to
connect each wire carefully to prevent line crossing.
6.3.3. Controls
6.3.3.1. Inside Controls
There are eight switches on the inside of your ICS-500. Looking into
the box they will be on the extreme right hand side on the boards with
the large black relays. Each switch has two positions: Heat, and Cool.
It is important that the switch be in the right position according to the
equipment on that particular stage. (If you have fans on a stage, that
stage’s switch should be in the cool position.)
The position of the switch determines whether the stage is turned on if
temperature reaches the high or low limit. Obviously it is important
for heaters to not turn on when temperature is dangerously high.
J4
J5
VR4
H
E
A
T
CR4
SW4 C
O
O
L
VR3
H
E
A
T
CR3
SW3 C
O
O
L
VR2
H
E
A
T
CR2
SW2 C
O
O
L
RLY4RLY3RLY2
COOL
HEAT
August 26, 1991 L.SelfCopyright C 1991,1992 PCB 115 (REV 0)
These switches
must be in the
proper position.
6.3.3.2. Front Panel
The only controls on the outside of the contactor panel are the
“Auto/Off/On” toggle switches. These switch positions allow you to
select whether the stage will be on continuously, be turned on or off as
needed by the controller, or turned off unless needed by the back-up
system. An indicator light is provided for each stage to show at a
glance which stages are running.

Integrated Control System 500 18
7. Operation
7.1. Curtain Operation
7.1.1. Standard
If the controller sees that temperature inside the house is above target temperature it will
signal the curtains to open. When the cycle time has elapsed the controller will begin
opening the curtain. (The curtain will move for the time set by the Runtime Adjust
setting.) If temperature cannot be maintained by the curtains alone, the controller will
stage in fans as directed by the stage program.
7.1.2. Tunnel (Enhanced Version Only)
When outside temperature has risen above the Outside Sensor Control High Limit
setting, the controller will go into “tunnel mode”. When this event occurs, the controller
will begin shutting the primary curtain while opening the tunnel inlet curtain.
During the time the curtains are re-aligning, the controller is waiting to see the signal
that the tunnel inlet curtain has opened, and that the primary curtain has closed. This
waiting period is counted down in the display. If the controller has waited for 300
seconds (5 minutes) and the inlet curtain has not moved, the controller will “abort” the
attempt to enter tunnel mode. The next paragraph explains this “tunnel mode abort.”
"Tunnel mode abort" is designed to prevent having a closed house
with no cool stages active. The primary curtain is immediately lowered
to completely open, and the inlet curtain is actuated open. All cool
stages are activated except for stage 8 (which depending on the
program could be a fogger).
You will be alerted to this condition by the continual flashing of the
TARGET and OSC HIGH LIMIT lights.
The machine will not return to normal operation until you reset it by
turning the OSC HIGH LIMIT dial all the way to the left, and then all
the way back to the right within 1 second. At this point the inlet
curtain is closed once again, emergency stages are cut off, and normal
operation is resumed.
Once the primary curtain is closed, (the inlet should be fully open) the controller will
turn on the appropriate tunnel stages. While in tunnel mode, the controller will always
have at least one tunnel stage on.
When outside temperature drops back down to a safe temperature for conventional
ventilation (factory set at 7 degrees below the OSC high limit temperature you set) the
controller will re-align the curtains for natural ventilation. Since it is safe to believe that
this temperature will still be above target temperature, the controller will always open
the primary curtain completely upon exiting tunnel mode. If the curtains need to close,
they will do so when their cycle time begins again.
If the controller begins to enter tunnel mode by adjusting the controls on the facepad,
(By turning the OSC limit dial) the “OSC” light will flash repeatedly for several
seconds, to alert you to this condition. If this was done by accident, you will be able to
stop tunnel mode by re-adjusting the OSC high limit dial.
The inlet curtain will either be completely open or completely closed at all times--no
cycling or running.