Intellidyne IntelliCon HW+ Specification sheet

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).
STANDBY MODE
ECONOMIZER MODE
HEATING MODE
HEATING / LO LIM
HEAT TEMP = xxx˚F
DOM TEMP = xxx˚F
A SAVE = xx.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]

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 controller’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 it 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]

OPERATING MANUAL and INSTALLATION INSTRUCTIONS for Form HW+3250 rev 7.2
IntelliCon®-HW+
HOT-WATER HEATING SYSTEM ECONOMIZER
M A X E C O N = D I S A B L D
M A X STBY= D I S A B L D
This is a Yes/No type of parameter
WARNING: This parameter will clear 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).
For all of the parameters that follow, after making a change and the “**DATA
SAVED**” message is displayed, you will be given an additional chance to
change that parameter again, before advancing to the next programmable
parameter.
This is an Increase/Decrease type of parameter
This parameter indicates the pre-purge time currently programmed into the
controller (default value = 000 seconds). To change this setting, plug in the sensor
to the appropriate jack to increase or decrease the value.
OR
This is a Yes/No type of parameter
The controller will prompt you to change to whatever value is NOT currently
selected (default value = F). For example, if the parameter is currently set for
degrees F, the only choice will be to change to degrees C. This setting will alter the
indicated values of the next two (2) programmable parameters, and how the
indicated temperatures are displayed when the controller is in operation. Plug into
the top jack to change the parameter, or plug into the lower jack to answer NO (and
proceed to the next parameter, or do nothing and allow the 7 second delay to
expire and proceed to the next parameter).
OR
This is an Increase/Decrease type of parameter
This parameter is used by the controller to set the low-limit temperature for the
heating water. When the heating water temperature goes below this setting,
“HEATING/LOLIM” will be displayed, and the controller will no longer attempt to
achieve any savings and will return control to the operating-control. To change this
setting, plug the sensor into the appropriate jack to increase or decrease the value.
The indicated value will be what is currently set in the controller (default = Auto).
When in “AUTO” and only the heating water sensor is used, the default value of
120˚F / 49˚C will be used. When in “Auto” and both sensors are used the default
value of 145˚F / 62˚C will be used. To change this setting, plug the sensor into the
appropriate jack to increase or decrease the value. The range of adjustment is
between 90˚F/32˚C and 180˚F/82˚C. Remove the sensor when the desired value is
reached.
OR
This is an Increase/Decrease type of parameter
This parameter is used by the controller to set the low-limit temperature for the
domestic hot water. When the domestic water temperature goes below this setting,
“HEATING/LOLIM” will be displayed, and the controller will no longer attempt to
achieve any savings and return control to the operating-control. To change this
setting, plug the sensor into the appropriate jack to increase or decrease the value.
The indicated value will be what is currently set in the controller (default = 120˚F /
49˚C). The range of adjustment is between 90˚F/32˚C and 180˚F/82˚C. Remove
the sensor when the desired value is reached.
OR
This is a Yes/No type of parameter
This parameter controls whether or not the Economizer Time accumulator is
displayed. The controller will prompt you to change to whatever value is NOT
currently selected (default value = ON). For example, if the parameter is currently
set for “ON”, the only choice will be to change to “OFF”. Note – the accumulator is
active even if not displayed. Plug into the top jack to change the parameter, or plug
into the lower jack to answer NO (and proceed to the next parameter, or do nothing
and allow the 7 second delay to expire and proceed to the next parameter).
OR
This is a Yes/No type of parameter
This parameter controls whether or not the Burner Run-Time accumulator is
displayed. The controller will prompt you to change to whatever value is NOT
currently selected (default value = ON). For example, if the parameter is currently
set for “ON”, the only choice will be to change to “OFF”. Note – the accumulator is
active even if not displayed. Plug into the top jack to change the parameter, or plug
into the lower jack to answer NO (and proceed to the next parameter, or do nothing
and allow the 7 second delay to expire and proceed to the next parameter).
OR
This is a Yes/No type of parameter
This parameter controls whether or not the Average Savings accumulator is
displayed. The controller will prompt you to change to whatever value is NOT
currently selected (default value = ON). For example, if the parameter is currently set
for “ON”, the only choice will be to change to “OFF”. Note – the accumulator is active
even if not displayed. Plug into the top jack to change the parameter, or plug into the
lower jack to answer NO (and proceed to the next parameter, or do nothing and allow
the 7 second delay to expire and proceed to the next parameter).
OR
This is an Increase/Decrease type of parameter
This parameter limits the maximum amount of time that the controller is allowed to
remain in the Economizer Mode. To change this setting, plug the sensor into the
appropriate jack to increase or decrease the value. The indicated value will be what
is currently set in the controller (default = DISABLED). The range of this adjustment is
between 10 and 120 minutes and “DISABLED. Remove the sensor when the desired
value is reached. If the controller goes in to the heating mode as a result of this
feature, the message “HEATING/MAX ECON” will be displayed.
OR
This is an Increase/Decrease type of parameter This feature of the controller is to limit the
maximum amount of time that the controller is allowed to remain in the Standby Mode
as a means of monitoring the internal electronics against failure. If a heating call is not
sensed within the prescribed time period, the timer will expire and the control will take
itself out of the circuit (fail-safe). A period (“.”) will be appended to the “STANDBY
MODE.”message to indicate that this timer has expired for service personnel. It will
only reset upon sensing a call from the aquastat. Cycling power to the control will
NOT reset the timer.
To change this setting, plug in the sensor when prompted. The indicated value will be
what is currently set in the controller (default = 180 minutes). The range of this
adjustment is between 45 and 180 minutes and “DISABLED. Remove the sensor
when the desired value is reached. Disabling this function is NOT recommended!
This condition is not necessarily a fault. It will occur naturally if the heating system has
been “off” or there are long periods of time between aqua-stat heating calls. The only
time that this should be considered a problem is if the controller is in “STANDBY
MODE.” and the burner is running. This would indicate a failure of the on-board
electronics and that the IntelliCon has taken itself out of the circuit.
AFTER THE LAST PARAMETER IS REACHED THERE WILL BE A
BRIEF DELAY AND THE CONTROLLER WILL RESET. DURING THIS
TIME THE SENSOR(S) SHOULD BE RECONNECTED OR THE
CONTROLLER WILL ATTEMPT TO GO INTO THE CONFIGURATION
MODE AGAIN. IF YOU DON’T REACT QUICKLY ENOUGH, SIMPLY
TURN THE CONTROLLER OFF, CONNECT THE SENSOR(S) AND
TURN THE CONTROLLER BACK ON.
RESET TIMERS?
PREPURGE=xxx SEC
FOR DEGREES C?
FOR DEGREES F?
H LO L IM = x xx ˚F
H LO L IM = x xx ˚C
D LO L IM = x xx ˚F
D LO L IM = x xx ˚C
ECON TIMER OFF?
ECON TIMER ON?
RUN TIME OFF?
RUN TIME ON?
A SAVING OFF?
A SAVING ON?
MAX ECON=xxx MIN
MAX STBY = xxx MIN
Intellidyne LLC • 5507 Nesconset HWY STE10 PMB148 • Mount Sinai, NY 11766, USA • Email [email protected]

OPERATING MANUAL and INSTALLATION INSTRUCTIONS for Form HW+3250 rev 7.2
IntelliCon®-HW+
HOT-WATER HEATING SYSTEM ECONOMIZER
Fig. 1a Fig. 1b
FOR 220V POWER USE VIO WIRE AND TAPE-OFF BLK
FOR 115V POWER USE BLK WIRE AND TAPE-OFF VIO
WIRING NOTE:
OR WIRE-NUT
INDIVIDUALLY TAPE
SEE WIRING NOTE
BLU = 24V
SEE WIRING NOTE
SEE WIRING NOTE
SEE WIRING NOTE
OR WIRE-NUT
INDIVIDUALLY TAPE
OR WIRE-NUT
INDIVIDUALLY TAPE
BLU = 24V
24V CALL
THE WHITE TO THE 24V COMMON. THE BLACK AND VIOLET WIRES ARE NOT USED AND SEPARATELY TAPED)
(FOR 24V POWER & CONTROL THE BLUE WIRE WOULD BE CONNECTED TO THE 24V HOT,
COMMON
HOT
BRN = 115/230V
GRY = 24V
RED
YEL
WHT
GRY = 24V
24V
115/220V
BURNER
EXISTING
BOILER
HERE
BROKEN
TEMP.
DROP
CONNECTION
TYPICAL 115/220V POWER / 24V CONTROL -- BOILER BURNER CIRCUIT
HOT
MASTER
BOILER SWITCH
COMMON
AQUASTAT
POWER
EXISTING
COMMON
HOT
HERE
BROKEN
CONNECTION
BOILER SWITCH
MASTER
POWER
TYPICAL 115/220V POWER & CONTROL -- BOILER BURNER CIRCUIT
BURNER
AQUASTAT
BOILER
DROP
TEMP.
RED
YEL
BRN = 115/230V
WHT
WIRING NOTE: The IntelliCon unit has MULTI-VOLTAGE capability and has separate common wires for the Power and
Control circuits. It is necessary that these wires be connected to the appropriate commons for the circuit or the unit will
not function properly. Unused wires MUST be separately taped!
IMPROPER VOLTAGE SELECTION WILL DAMAGE THE UNIT and Void the Warranty.
Fig. 2
Fig. 3
THIS
SENSOR
TEMPERATURE
TYRAPS
NEW STYLE SIDE VIEW
PIPE
TOWARDS
SIDE
ON SENSOR
INTO JACK
CABLE PLUGS
OUTFLOW
PIPE
INSULATION
TAPE
PIPE
OUTFLOW
TAPE
TEMPERATURE
SENSOR WIRE
Intellidyne LLC • 5507 Nesconset HWY STE10 PMB148 • Mount Sinai, NY 11766, USA • Email [email protected]