Intellidyne IntelliCon-CHS Specification sheet

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 [phone] • Fax [phone]
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. Burden
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.

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 [phone] • Fax [phone]
“RETURN” (Condensate Return Sensor) ***
If a Heat-Timer is present or condensate return temperature indication and
sensing is desired, plug this temperature sensor in to the ‘Return' jack
(J3), and attach the sensor to the condensate return pipe as close to the
boiler as possible or upstream of condensate pump (if present). Mount the
sensor (as shown in fig. 2). While this sensor is not required for proper
operation, it does enhance the operation of the IntelliCon®-CHS and
should be used if a Heat-Timer is present.
***This temperature sensor is not included and must be ordered
separately.
Heat-Timer / Summer-Winter Switch
A Dry (No Voltage) contact should be connected to the S/W SW.
terminals. The contact should be closed for summer operation or when
there is a domestic water call when used with a Heat-Timer.
Checkout
Recheck the wiring one last time and make sure that all of the installed sensors
are plugged into the proper jacks. The sensors are only detected during
power-up. Set the IntelliCon®power switch to ‘OFF/BYPASS’ and restore
power to the boiler. Next set the switch to ‘ON’. The display will illuminate
and will then indicate the results of a sequence of status checks of the
unit’s electronics. Next, it will check to see which sensors are attached
and indicate which; on the display. The installer should verify that each
sensor attached is detected by the unit. If an installed sensor is not
detected, power the unit down and remove and reattach the sensor’s
connector. Restore power. If the sensor is still not detected; replace the
sensor with another. After these tests are successfully completed, the unit
will display one of the operating mode messages depending upon the
pressure/temperature of the boiler at power-up. If the IntelliCon®comes
on and goes into the ‘Standby Mode’; note the pressure-control setting
and force a burner call by temporarily setting the control higher and
verifying the change of mode of the IntelliCon®. Make sure to return the
pressure-control to its’ previous setting. If the IntelliCon®does not come
out of ‘STANDBY MODE’ when the boiler’s pressure control is calling for
the burner to run, the unit is probably miswired; see the WIRING NOTE.
After completion of the above checkout procedure and observation of a full
boiler cycle, the installation is complete.
Service and Troubleshooting
The IntelliCon®-CHS does not require any maintenance and will provide
years of trouble free operation. The unit may be disconnected at any time
by putting the power switch to the ‘OFF/BYPASS’ position. In this position,
the unit has no effect on the system and the boiler is wired as it was prior
to the IntelliCon®installation. This allows service personnel to diagnose
boiler problems without the IntelliCon®intervening.
If at any time the power indicator on the front panel blinks, a sensor fault
has been detected. A "FAIL" messages will be displayed, for the faulty
sensor, on the LCD display. If this occurs, the unit automatically
disconnects itself and returns full control to the boiler. If a sensor fault
message appears; call your installer for service.
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.
8. For CE compliance, all wiring and sensor leads must be installed in
grounded metallic conduit.
IMPROPER VOLTAGE SELECTION MAY DAMAGE THE UNIT AND VOID
THE WARRANTY.
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,
Steam Intedation in either PSI or KPa, Steam Pressure Low-Limit,
Domestic Water Low-Limit, Return Water Low-Limit, Return Water
Differential, Maximum Economizer Hold-Off Time, Standby-Timer
Override, and whether or not the Economizer Time and/or Burner
Run-Time Hour accumulators are Displayed. The system may also be
returned to factory default values and the 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 USING THE FOUR (4)
SWITCHES LOCATED IN THE WIRING COMPARTMENT ABOVE THE
SENSOR CONNECTOR JACKS
PROGRAMMING MAY BE STOPPED OR ABORTED AT ANY TIME BY
BACKING OUT OF THE MENU STRUCTURE OR BY TURNING THE
CONTROLLER OFF. ANY PARAMETERS THAT WERE CHANGED
WILL REMAIN CHANGED.
Entering Configuration Mode:
To enter configuration mode, both the +/menu and -/menu pushbuttons
must be depressed simultaneously when the “Line Frequency = ??Hz”
screen is displayed. Pressing the buttons before or after this screen will
result in the unit NOT going into the configuration mode. Navigating the
menus, changing parameters, and confirmations are all done using the
appropriate pushbutton. Follow the on-screen instructions for switch
usage.
Changes made will be confirmed by indicating “**DATA SAVED**”.
After making a change and the “**DATA SAVED**” message is
displayed, you can move forward or backward in the menu structure
to make any additional changes before exiting Configuration Mode.
RESET TO DEFAULTS? -- This parameter will reset all of the
programmable parameters to factory defaults. It will not clear any of the
accumulators.
RESET RUN-TIME? -- This parameter will clear the Run-Time
accumulator.
(Note: This value is accumulated even if not being displayed.)
RESET ECONO-TIME? -- This parameter will clear the Economizer Time
accumulator.
(Note: This value is accumulated even if not being displayed.)
TEMP READING IN ˚F or ˚C-- The controller will indicate whatever value
is currently selected (default value = F). Using the pushbuttons, select the
desired setting and then press the enter pushbutton twice to accept the
change. This setting will alter the displayed values of the LOLIM
programmable parameters, and how the temperatures are displayed when
the controller is in normal operation.
STEAM READING IN PSI or KPa -- The controller will indicate whatever
value is currently selected (default value = PSI). Using the pushbuttons,

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 [phone] • Fax [phone]
select the desired setting and then press the enter pushbutton twice to
accept the change. This setting will alter the displayed value of the Steam
Pressure LOLIM programmable parameter, and how the steam pressure is
displayed when the controller is in normal operation.
P RANGE = 0-25 PSI (0–172 KPa) OR 0-145 PSI (0–1000 KPa) –
The controller will indicate whatever value is currently selected (default
value = 0- 25 PSI). Using the pushbuttons, select the desired setting and
then press the enter pushbutton twice to accept the change. Changing
this setting will erase any changes that may have been made to the Steam
Pressure LOLIM, and will reset the Steam Pressure LOLIM to the default
values for that range.
S/W SWITCH = NORMAL or REVERSE – This parameter allows
the direction of operation of S/W SW (summer/winter switch) to
be reversed. In NORMAL mode, a contact closure of the S/W SW
terminals would put the unit in to Summer Mode. In Summer
Mode the Steam Pressure is ignored and the controller only
responds to Domestic Water Temperature changes. In the
REVERSE mode a contact opening would have the same effect.
ET DISPLAY = ON/OFF? -- This parameter controls whether or not the
Economizer Time accumulator is displayed. Using the pushbuttons, select
the desired setting and then press the enter pushbutton twice to accept
the change. Note – the accumulator is active even if not displayed.
RT DISPLAY = ON/OFF? -- This parameter controls whether or not
the Burner Run-Time accumulator is displayed. Using the pushbuttons,
select the desired setting and then press the enter pushbutton twice to
accept the change. Note – the accumulator is active even if not displayed.
STEAM LOLIM = xxx PSI or KPa -- This parameter is used by
the controller to set the low limit below which the controller will no longer
attempt to achieve any savings and will return control to the operating-
control. The indicated value will be what is currently set in the controller.
The default values are 2 PSI (14 KPa) for the low pressure unit, and 22
PSI (155 KPa) for the high pressure unit. The +/Menu and -/Menu
pushbuttons will allow the setting to be changed between the minimum 1
PSI (7 KPa) to a maximum of 10 PSI (70 KPa) for a low pressure unit and
a minimum of 12 PSI (84 KPa) to a maximum of 32 PSI (224 KPa) for a
high pressure unit. If the steam pressure goes below this value while the
operating-control is calling for the burner to run, the controller will indicate
“HEATING/LOLIM” on the display.
DOMESTIC LOLIM = xxx ˚F(C) -- 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, the controller will
no longer attempt to achieve any savings and will return control to the
operating-control. The indicated value will be what is currently set in the
controller (default = 115˚F / 46˚C). The +/Menu and -/Menu pushbuttons
will allow the setting to be changed between the maximum (180˚F/82˚C)
and minimum (90˚F/32˚C) settings. If the ‘Domestic’ water temperature
goes below this value while the operating-control is calling for the burner to
run, , the controller will release the burner to run, and will indicate
“HEATING/LOLIM” on the display.
RETURN LOLIM = xxx ˚F(C) -- This parameter is used by the
controller to set the low-limit temperature for the condensate return. When
the condensate temperature goes below this setting, the controller will no
longer attempt to achieve any savings and will return control to the
operating-control. The indicated value will be what is currently set in the
controller (default = 90˚F / 32˚C). The +/Menu and -/Menu pushbuttons will
allow the setting to be changed between the maximum (180˚F/82˚C) and
minimum (70˚F/21˚C) settings. If the ‘Condensate’ temperature goes
below this value while in Winter Mode, and the operating-control is calling
for the burner to run, the controller will release the burner to run, and
indicate “HEATING/LOLIM” on the display.
RETURN DIFF = xx ˚F(C) -- This parameter is used by the
controller to set the point at which the burner will be allowed to run when in
Winter Mode. In Winter Mode, the burner will be inhibited from firing as
long as there is energy in the condensate. When the condensate
temperature goes below this setting, the controller will no longer attempt to
achieve any savings and will return control to the operating-control. The
indicated value will be what is currently set in the controller (default = 10˚F
~ 6˚C). The +/Menu and -/Menu pushbuttons will allow the setting to be
changed between the maximum (25˚F/18˚C) and minimum (5˚F/3˚C)
settings. If the ‘Condensate’ temperature goes below this value while in
Winter Mode, and the operating-control is calling for the burner to run, the
controller will release the burner to run, and indicate “HEATING” on the
display.
PREPURGE = xxx SEC -- This parameter indicates the pre-purge time
currently programmed into the controller (default value = 000 seconds).
The +/Menu and -/Menu pushbuttons will allow the setting to be changed
between the maximum (240 Secs.) and minimum (000 Secs.) settings.
This setting is important for proper run-time hours accumulation.
MAX ECON = xxx MIN -- This feature of the controller is to limit the
maximum amount of time that the controller is allowed to remain in the
Economizer Mode. The indicated value will be what is currently set in the
controller (default = 30 minutes). The +/Menu and -/Menu pushbuttons will
allow the setting to be changed between “Disabled” or the maximum (120
Mins.) and minimum (5 Mins.) settings. If the controller goes in to the
“HEATING MODE” as a result of this feature, there will be a period (“.”)
appended to the word “MODE” on the display.
MAX STBY = xxx MIN -- 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.
The indicated value will be what is currently set in the controller (default =
180 mins). The +/Menu and -/Menu pushbuttons will allow the setting to be
changed between “Disabled” or the maximum (180 Mins.) and minimum
(45 Mins.) settings.
DISABLING THIS FUNCTION IS NOT RECOMMENDED!
This condition is not necessarily a fault and will occur naturally if the
heating system has been “off” or there are long periods of time between
aquastat 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.
FOLLOW THE SCREEN INSTRUCTIONS TO EXIT THE
CONFIGURATION MODE AND REBOOT THE CONTROL.

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 [phone] • Fax [phone]
SUMMER-WINTER OPERATION OR IF A HEAT-TIMER
WHEN THERE IS A DOMESTIC HOT-WATER CALL WHEN
SHOULD CLOSE WHEN SUMMER MODE IS DESIRED OR
WINTER = N.O.
SUMMER = N.C.
SUMMER/WINTER SWITCH
S/W SW.
E-GND
GND
TYPICAL 220V POWER / 24V CONTROL -- BOILER BURNER CIRCUIT
IntelliCon Wiring Compartment
SUMMER-WINTER OPERATION OR IF A HEAT-TIMER
PRESSTROL
BOILER
TYPICAL 115 POWER & CONTROL -- BOILER BURNER CIRCUIT
Fig. 1A
DOMESTIC HOT-WATER. A N.O. DRY CONTACT
WHEN THERE IS A DOMESTIC HOT-WATER CALL WHEN
SHOULD CLOSE WHEN SUMMER MODE IS DESIRED OR
USED IN CONJUNCTION WITH A HEAT-TIMER.
IS USED ON A BOILER THAT ALSO GENERATES
POWER
NEUTRAL
MASTER
BOILER SWITCH
HOT CONNECTION
PRESS.
DROP
BROKEN
HERE
EXISTING
BURNER
BOILER SWITCH
POWER
L2
L1
220V
MASTER
DOMESTIC HOT-WATER. A N.O. DRY CONTACT
USED IN CONJUNCTION WITH A HEAT-TIMER.
IS USED ON A BOILER THAT ALSO GENERATES
CIRCUIT CONNECTIONS
IntelliCon Wiring Compartment
NOTE: S/W SW TERMINALS MUST BE USED IF THERE IS
WINTER = N.O.
SENSOR CONNECTORS
SUPPLY DOM.
GND
E-GND
S/W SW.
RETURN
BACK
-/MENU
+/MENU
SUMMER/WINTER SWITCH
SUMMER = N.C.
ENTER
COMMON CALL
115/220
24
BURNER
24
115
220
COMMON
BURNER CONTROL CONNECTIONS
INCOMING POWER
NOTE: S/W SW TERMINALS MUST BE USED IF THERE IS
SENSOR CONNECTORS
SUPPLY RETURNDOM.
BACK ENTER
-/MENU
+/MENU
24V COMMON
Fig. 1B
24V CALL
PRESSTROL
BOILER
24V
HOT BROKEN
PRESS.
DROP
HERE
CONNECTION
EXISTING
BURNER
CONNECTIONS
INCOMING POWER
115/220
24 CALL
BURNER 115
220 24
CIRCUIT CONNECTIONS
BURNER CONTROL
COMMON
COMMON
WIRING NOTE:
The IntelliCon unit has MULTI-
VOLTAGE capability and has separate return
connections for the Power and Control circuits. It is necessary that these wires be connected to the
appropriate returns for the circuit or the unit will not function properly. For convenience, two (2) “Common”
connections are provided in the “Power” connection area and are for connection to the control circuit
common if it is from the same source as the power (see Fig. 1a). Fully insulated connectors must be used.
IMPROPER VOLTAGE SELECTION WILL DAMAGE THE UNIT and Void the Warranty.
Fig. 3
Fig. 2
TEMPERATURE
THIS
SENSOR
TYRAPS
SIDE VIEW
PIPE
TOWARDS
SIDE
ON SENSOR
INTO JACK
CABLE PLUGS
OUTFLOW
PIPE
SENSOR WIRE
TAPE
PIPE
OUTFLOW
INSULATION
TAPE