OPERATING MANUAL and INSTALLATION INSTRUCTIONS for Form FA3300 build_198
IntelliCon®-FA
FORCED-AIR HEATING SYSTEM ECONOMIZER
Description
The IntelliCon®-FA is a patented microprocessor-based fuel-saving device for
forced-air (warm-air) heating systems. The controller reduces fuel consumption and
burner emissions by actively managing the burner, in conjunction with the
thermostat, to operate the furnace in a more energy efficient manner. The controller
indicates average theoretical savings. 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.
This unit is not intended for use on milli-volt or self-powered gas burner
systems.
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 switch on the unit to the ‘ON’ position activates the
control. The LCD display indicates the various ‘modes’ of operation of the control,
sensed temperatures, savings and economizer and burner run-times. The possible
messages and their explanation are:
The space temperature is satisfied and the thermostat is not calling for the furnace to
fire.
The thermostat is calling for the burner to fire and the controller is allowing the
burner to fire.
Note: A period (.) or colon (:) may be appended to the message.
.= The period signifies that the Discharge-Air Terminal Temperature has been
established.
:= The colon indicates that the Maximum Economizer Hold-Off timer has enabled
the burner.
The controller has turned the burner Off even though the thermostat is calling for the
burner to fire.
During normal operation, one of the above messages will be alternated with the
messages below.
OR
“DA TEMP = xxx˚” - The measured value of the furnace’s discharge-air temperature
is displayed in degrees F or C (see Programming section). This message will NOT
appear if the optional sensor is installed
“DA = xxx˚RA = xxx˚” - The measured value of both the discharge and return air
temperatures in degrees F or C (see Programming section). This message will only
appear if the optional sensor is installed (see “Sensors” section of these
instructions).
In the event that the unit detects a sensor fault, full control of the burner is returned
to the existing controls. The ‘Power/Normal’ indicator will blink, and the following
message will be displayed:
?? = DA and/or RA
If this message appears, see the instructions under Service and Troubleshooting.
The calculated average savings of burner cycles since commissioning of the
controller (A = Average).
Note: This message will indicate N/A until there is sufficient data to perform the
calculations.
Total hours of Economizer time. (maximum = 65,535.9 hours).
Total hours of Burner run-time. (maximum = 65,535.9 hours).
Installation
The controller is electrically installed in series with the burner control device as
shown in the wiring diagrams contained in these instructions. Check and determine
the voltages of the burner control circuit and power circuit prior to installation. FOR
SAFETY, POWER TO THE FURNACE MUST BE DISCONNECTED DURING
INSTALLATION.
Positioning
The unit must be protected from the elements and may be mounted on the
equipment either vertically or horizontally. The unit should be mounted directly on
the existing electric enclosure via the unit’s standard ½” electrical fitting or within the
enclosure using an accessory mounting bracket. For mounting in the elements, a
rain-tight mounting enclosure is available.
Wiring
All wiring and connections must comply with Local and National Electrical
Codes. The unit should be wired as shown in the wiring diagram(s) on the
reverse side. It is important to read all of the instructions. Ensure that POWER
TO THE UNIT IS OFF DURING INSTALLATION and that all unused leads are
individually taped/insulated.
Sensors
Mount the discharge air sensor on the Furnace’s discharge air ductwork/plenum as
close to the furnace as possible but at least 18” from the heat-exchanger. Locate an
unobstructed area on the ductwork/plenum and (making sure there is nothing
behind it) drill a 5/8” dia. hole for the sensor to extend into the airflow. Attach the
mounting bracket to the duct using # 8 hardware. If the sensor is installed exposed
to the elements or mounted within the ductwork, the sensor must be installed using
the optional rain-tight enclosure kit which may be obtained from Intellidyne (part no.
4066). Make sure that the sensor is oriented according to the direction of airflow as
shown on the mounting diagram. Plug the sensor’s connector into the ‘Discharge
Air’ jack located on the side of the unit.
Additional economies can be realized through the use of a return air temperature
sensor. Mount the return air sensor on the Furnace’s return air duct in a similar
fashion to that of the discharge air sensor. Plug the sensor’s connector into the
‘Return Air’ jack located on the side of the unit.
The controller will not work without the discharge air sensor and will work
improperly if the plugs are in the wrong jacks. Use of the return air sensor is
optional but should be used whenever possible.
Checkout
Recheck wiring one last time and make sure that the temperature sensor(s) is
plugged into the proper jack(s). The sensors are only detected during power-up.
Set the controller to ‘Off/Bypass’ and restore power to the furnace. Note the
thermostat setting and then change that setting all the way down. Place the switch
on the controller to ‘On’. After a brief check of the electronics, 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 unit will not function
properly. If the green indicator is blinking or if the display does not verify the
installed sensor(s), turn the unit ‘Off’ and check the sensor installation. After the
sensor-check, verify that the unit is in . If in , force a
heat call (burner to fire) by temporarily raising the thermostat all the way up and
verifying that the unit changes to mode and that the burner fires.
Make sure to return the thermostat to its’ original setting. This indicates that the
control is operating normally. If the unit did not change modes and the burner fire
when the thermostat was adjusted the unit is probably wired incorrectly.
Service and Troubleshooting
After Installation and Checkout, the controller requires no maintenance and will
provide years of trouble free operation. The unit may be disconnected at any time
by placing the slide switch in 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 controllers
installation. This allows service personnel to troubleshoot or work on the furnace
without the controller intervening.
If at any time the light on the front panel blinks continuously, a sensor is not
operating properly.
If the message is displayed the control
should be placed into the OFF/Bypass position.
If any of the above trouble conditions have occurred the control
has taken itself out of the circuit and returned full control to the
pre-existing controls. The Installer should be called for service.
STANDBY MODE
BURNER ENABLED
ECONOMIZING
DA TEMP = DA = xxx˚RA = xxx˚
CHECK ?? SENSOR
A SAV = xx.x%
ET HRS = xxxxx.x
RT HRS = xxxxx.x
STANDBY MODE
BURNER ENABLED
LINE SYNC FAILED SYSTEM BYPASSED
STANDBY MODE
Intellidyne LLC • 5507 Nesconset H
WY STE10 PMB148 • Mount Sinai, NY 11766, USA • Email [email protected]
