Industrial Commercial Equipment Manufacturing LTD. 51 Aikins Street Winnipeg, MB Canada, R2W 4E3 HTDM INSTALLATION, OPERATION AND MAINTAINANCE MANUAL ATTENTION: Read this manual, unit submittal sheets and all labels attached to the unit carefully before attempting to install, operate or service these units! Check unit data plates for type of gas, model number and serial numbers. Retain this document for future reference.
Table of Contents Receiving and Warehousing General Handling instructions General Installation Notes Clearance to Combustables Connecting the Flue Electrical Connections Gas Piping Gas Vent Duct Furnaces Cooling High Altitude Indoor Units General Operating Instructions Start Up Procedures Precautions Gas Units Start Up Shut Down Emergency Shut Down Service Shut Down Recommended Quarterly Maintenance Recommended Yearly Maintenance ICECON II Operators Manual ICECON II Controller Normal Start Up Sequence Heat
RECEIVING AND WAREHOUSING Inspect the unit upon arrival for any shipping damage. If any part is missing or damaged, Mark bill of lading as to damage and notify the carrier at once. If the unit cannot be installed immediately, store it and its accessories in a clean and dry place. GENERAL HANDLING INSTRUCTIONS A qualified and experienced crane operator must do all rigging. General rigging methods should be followed in all cases: a) Spreader bars must be used when lifting equipment.
have been designed for, and certified to comply with, CAN/CGA2.8. b) Installation must be made in accordance with local codes or in absence of local codes with ANSI Standard Z223.1-1992 (N.F.P.A. No.54) “National fuel Gas Code” or the latest edition of all ANSI and NFPA standards. Standards referred to in these installation instructions are in effect at the time of certification. ANSI Standards are available from the American Gas Association 1515 Wilson Boulevard, Arlington, Virgina 22209.
Ducts connected to the furnace shall have removable access panels on both the upstream and downstream sides of the furnace. These openings shall be accessible when the furnace is installed and shall be sized to allow the observation of smoke or reflected light inside the casing to indicate the presence of leaks in the heat exchanger. The covers for the openings shall be attached in such manner as to prevent leaks. The furnace must not be operated in the presence of chlorinated vapours.
be installed between the unit’s flue connection and the type “B” vent. NOTE: For venting diagram see Appendix C. ELECTRICAL CONNECTIONS a) This unit has been examined and tested for compliance with CSA C22.2 no.0, CSA C22.2 no.3 and the NED code. b) All electrical work must conform to the requirements of the current NEC and CSA standard C22.1, Canadian Electric Code part I, and local ordinances. c) Control voltage is as indicted on the rating plate. d) Follow the wiring diagram supplied with the unit.
be provided upstream of the piping to unit and should be labelled for quick identification. Colour coding of gas piping is also recommended. In addition: a) Carefully check the unit rating plate for fuel type and supply pressure. b) If required, locate the high-pressure regulator at least five feet from the unit. c) Gas lines must not be located in such a way as to hinder access to the unit.
COOLING When installed downstream from a refrigeration system. Condensation will form and provisions shall be made to dispose of condensate. HIGH ALTITUDE As per June I, 1998 all HTDM units are derated four percent of maximum input of each 1OOOft(305m) elevation above sea level. INDOOR UNITS Install an indoor unit in such that the gas ignition control system is not directly exposed to water spray, rain or dripping water.
e) Lubricate (if necessary) the burner and main fan motors. The specification on the motors for grease and oil shall be adhered to. f) Check heater outlets for obstruction. g) Check all fuse blocks to determine that all fusing is insta11ed. h) Set the operating controls (e.g. thermostat, remote panel switches) so as to allow heating operation of the unit. i) Reset the motor starter by pushing the reset button, if so equipped. Ensure all blowers are rotating in the correct rotation.
flame signals etc.) Readings obtained in the field should not deviate significantly from those obtained at the factory. SHUT DOWN 1. EMERGENCY SHUT DOWN a) Set disconnect switch to "off' position. b) Close the manual main fuel valve. c) Set the burner on-off switch to "off'. 2. SERVICE SHUT DOWN a) Set the burner toggle switch to "off' position. b) Close the manual main fuel valve. c) Set the operating controls, (e.g. thermostat, remote panel switches), so as to prevent heating operation.
o) Oil burner fan. p) Check all bearing to ensure tightness on shaft and lubricate if necessary. q) Check ignition spark and adjust gap if necessary. 2. RECOMMENDED YEARLY MAINIENANCE a) Perform the monthly quarterly maintenance recommended. b) Inspect blower wheels and housing, clean if necessary. c) Inspect all set screw on blower wheels and pulleys to ensure that they are secured to their respective shafts d) Check flame supervisor controller. e) Inspect all operating and safety controls.
ICECON II OPERATORS MANUAL 12
I.
II. NORMAL START-UP SEQUENCE 1) Call For Heat The ICECON 2 controller will indicate power by illuminating the power LED (light emitting diode). The combustion blower is ramped to full speed. Upon proof of closer of the modulating gas valve the auto heating light is energized. 24VAC power is sent to the purge timer coil. Upon the timing out of the purge timer the combustion blower will ramp to minimum speed for trial for ignition.
3) External Modulation Control The ICECON II controller is capable of responding to a 0-10Vdc or 4-20mA signals. To configure the ICECON II controller to respond to an external signal the RSP and Mod/std check boxes (In the software interface) must not be checked. The control signal connects to terminals J3-25 and J3-26. The ICECON II controller will remain in control of errors and will lock out if any error condition occurs. The BMS has complete control over the discharge temperature.
Switching From a mA control signal to VDC Remove the ICECON II control cover plate. In the lower right hand area of the circuit board there is a small black jumper label ed “4-20mA enable”. This jumper is left in place when receiving a 420mA control signal and is removed when using a 0-10Vdc signal.
III. AVAILABLE OPTIONS (Software controlled) 1) Space Override Units equipped with this option will modulate normally in one of the above heat modes until continuity is sensed between terminals J19 and J21. Upon sensing continuity unit will de-energize the auto indicator LED and ramp to full fire until the contacts are opened. Regular heat mode operation will be resumed once the contacts between J19 and J21 are opened.
operation for a period of time to allow for cooling of the heat exchanger. 5) Fan on in Standby Mode With this option the main supply fan will remain in operation regardless of the call for heat when the Standby option is selected. During transition between heat and standby operation the supply fan may cycle on and off for a short duration.
IV. ERROR SIGNALS 1) High Limit Error This condition will occur when the ICECON2 controller has a duct temperature greater than the factory set point or the discharge sensor contacts are in the open condition. This condition is indicated by the illumination of LED numbers 5 and 8. The unit will indicate the high limit error and will lock until reset. Led numbers 5 and 8 will illuminate.
indicated by the illumination of LED numbers 5, 6 and 8. The unit will lock out and will require resetting to reinitiate.
V. Trouble Shooting AIR PROVING ERROR • • • FLAME ERROR • • • • • • HIGH LIMIT ERROR • • • • LOW LIMIT ERROR • • • • VALVE ERROR • • The ICECON2 controller has lost the Tachometer signal. Check combustion blower operation. Check tachometer sensor operation (see section ******). Check ICECON2 fuses The ICECON2 controller has lost the 24 VAC on terminal J22.
• • • NO DISPLAY ON ICECON2 CONTROLER • • BOARD WILL NOT ENTER HEAT MODE • • • UNIT WILL NOT MODULATE SUPPLY FAN DOES NOT INGAGE • • • • • lost communication with the modulating gas valve. Check that valve is powered and operating correctly. Check for signal (0-10VDC) on terminal J11. The unit will not fire until valve has proven closed (<=2.0 VDC signal on terminal J11) Check ICECON2 fuses Board requires 24VAC on terminal J2 for operation.
VI. Tachometer Test Procedure Old Style Tachometer Test (Pre 2000 units) 1. Insure that the sensor will be no further than ¼ “ from the magnet when aligned 2. With magnet NOT aligned with the tachometer verify 5VDC between red and black wires. 3. With magnet NOT aligned with the tachometer verify 5VDC between white and black wires. 4. Rotate blower wheel until magnet is aligned with Tachometer sensor. 5. Verify 5VDC between red and black wires. 6. Verify 0VDC between white and black wires.
VII. Discharge Sensor and RSP (Remote Set Point) Test Once the combustion curve has been set up and the board configured for stand alone the operation of the discharge sensor and RSP must be verified. To accomplish this the computer must be connected to an active ICECON II controller. With the system in heat mode activate the “Tools” pull down menu and select “I/O view”. A new screen is no displayed. On the lower right there are three buttons, “Read”, “5 second read” and “Exit”.
VII.
Appendix A 26
I. Programming the HTDM ICECON II controller. To correctly configure the ICECON series of controllers the ICECON software must be used to communicate with the controller. Factory training is required. Changes to the control program can cause poor combustion, improper or undesired operation. Software identification For the ICECON II controllers the icecon1.7b version of the software must be used.
The Main Interface This screen provides a view of the current settings contained in the ICECON2 controller. Various control values such as the high and low limits can be adjusted in this environment. The options that the controller is currently configured with are displayed in the upper right corner and are indicated by a check mark in the corresponding box. The combustion curve settings, six in total, located at the bottom of the screen cannot be adjusted in this environment.
System Tune Interface To access the combustion settings activate the tools pull down menu and select the system tune option. The screen displayed in figure 2 is now visible. Adjustments to the combustion curve can be made to any of the six points. The previous screen will not be updated until the user has left system tune mode. The Fan box allows the adjustment of the combustion blower set point at one of the 6 set points. By adjusting this value up or down the fan speed can be increased or decreased.
I/O View The I/O view option located in the tools menu is used as a real time diagnostic tool. The system will communicate a provide status of system safeties and operating points. High Limit, Low Limit and Ini Error indicate improper operation of the unit. Off will indicate normal operation will ON signal a lock out condition has occured. Air proving and flame detect provide information on the combustion blower and flame signal. ON indicates normal operation while OFF will confirm a loss of signal.
3. Mod/std. This when checked activates the internal modulation control routines. When checked the system will not respond to a BMS signal. 4. Space Override. When checked the ICECON controller will monitor terminals J3-20 and J3-21 for continuity. When continuity is detected the system will ramp to full fire and remain at this point, regardless of discharge temperature, until continuity is lost. 5. Standby Mode. When checked the ICECON II controller will operate in both heating and non-heating modes.
6. Low Limit. When a temperature below this set point is detected, after a 3-minute internal time delay, the ICECON II controller will de-energize J1-5 and J1-3 and lock out on “Low Limit Error”. Combustion Set Points Located across the bottom of the main screen of the ICECON application are the six combustion set points. Each point has three parameters that describe each point. The “Fan” box contains a number that controls the cycle time of the solid-state relay and triac control signal.
displayed the actual voltage to being sent the valve is displayed (1/2 system tune voltage). Once the valve has reached the low fire set point allow 10 seconds for sufficient sampling time of the fan speed. Click the “Next” button and the system will now display the second combustion point. Press “Send” to drive the system to this combustion point. Allow the actuator to travel and stop at the correct voltage. Allow 10 seconds to achieve an accurate rpm reading.
Saving a ICECON II Program Once a HTDM has been configure and all the combustion points have been set (these will vary from unit to unit) it is time to save an electronic copy. Activate the file pull down and click “Save as”. A new screen will pop up displaying the directory in which the file will be saved, the type of file being saved (*.ice…..don’t change this) and the name of the file to be saved. Change the name of the file to something meaningful (job number for example).
board will be receiving and false temperature reading of 58°F. 3. Valve Error. This will occur if the ICECON II controller loses communication with the ball valve. To operate the controller must receive the feed back signal form the ball vale whenever the ICECON II controller is powered. 4. Air Proving Error. If the signal from the tachometer is lost the board will lock out on this condition. To check for proper operation of the tachometer perform the Tachometer test located in the following section. 5.
Appendix B 36
ICECON1 to ICECON2 Upgrade 1. To operate correctly the unit must be equipped with a Belimo NF24-SR US(or factory approved optional actuator) and ball valve combination for gas modulation. The unit will not operate unless equipped with the correct actuator. 2. Uncouple the 6,8 and 10 pin connector from the ICECON1 controller. 3. Remove the ICECON1 controller from the control panel. 4. If necessary rearrange components to accommodate larger size of ICECON2 controller. 5.
Terminal J2-1 J2-2 J2-3 J2-4 J2-5 J2-6 J2-7 J2-8 Connect to Feedback from actuator (0-10VDC) Not used Black wire from discharge Red wire from discharge White wire from discharge *Black wire from tachometer *Brown wire from tachometer *Blue wire from tachometer Option 1 *Note: If equipped with a discharge sensor with red, white and black wire leads see option 2.
10. Strip ends of individual wires exposing approximately ¼ inch of wire. 11.
J1 Connector J2 Connector J3 Connector 40
Appendix C 41
