Smart ways to save energy IntelliCon INSTALLATION MANUAL

Smart ways to save energy IntelliCon INSTALLATION MANUAL, LLC 516-676-0777 www.llc.com 3/6/2006

Air Conditioning General Instructions: General Wiring Instructions 2-1 2 Stage Air Cooled Air Conditioners 2-1 Heat Pump System 2-2 York Heat Pumps 2-2 Typical Packaged HVAC System 2-3 Typical 24vac Split A/C Air Handler 2-4 Typical 208/230vac Split A/C Air Handler 2-4 AC or CAC in Outdoor Condensing Section 2-5 Trane with Honeywell W973 Logic Panel 2-6, 7, 8 Trane Voyager with Interface Board 2-9 Trane Voyager without Interface Board 2-10, 11 Honeywell T775 Applications 2-12 HEATING Beckett HeatManager Honeywell L7124A, C or L7148A 3-1 Honeywell L7124U 3-2 Honeywell L7148F 3-3 Honeywell L7224U Electronic Aquastat 3-4 Honeywell L8124A, C 3-5 Honeywell L8124E 3-6 Honeywell L8124G, L 3-7 Honeywell L8148A 3-8 Honeywell L8148E 3-9 Honeywell L8148J 3-10 Honeywell L8151A 3-11 Honeywell R7184A, B, P, U (Line Voltage Controller) 3-12 Honeywell R7184A, B, P, U (Low Voltage Controller) 3-13 Honeywell R7184A, B, P, U REVISION 5 Model 3-14 Honeywell R8182D 3-15 Honeywell R8182E 3-16 Honeywell R8182F 3-17 Honeywell R8184G, K, L, N Cad Cell Relay 3-18 Honeywell R8184M, P 3-18 Honeywell R8285D 3-19 Riello Model 40F5 3-20 Cad Cell Relays General Instructions 3-21 Honeywell R8184G, K, L, N 3-22 Honeywell R8184M, P 3-22 Honeywell R7184A, B, P, U 3-23 5/30/2006 3

HEAT TIMER CHS/CHW with Mechanical Heat Timer 3-25 CHS/CHW with MPC Heat Timer 3-26 LCH with Mechanical Heat Timer 3-27 LCH with MPC Heat Timer 3-28 LCS with Mechanical Heat Timer 3-29 LCS with MPC Heat Timer 3-30 HW with Riello Model 40F5 3-31 Honeywell Aquastats (see Beckett HeatManager also) L7124A, C 3-32 L7124U 3-33 L7148F 3-34 L7224U Electronic Aquastat 3-35 L8124A, C 3-36 L8124E 3-37 L8124G, L 3-38 L8148A 3-39 L8148E 3-40 L8148J 3-41 L8151A 3-42 R7184A, B, P, U, (Line Voltage Controller) 3-43 R7184A, B, P, U, (Low Voltage Controller) 3-44 R7184A, B, P, U, REVISION 5 Model 3-45 R8182D 3-46 R8182E 3-47 R8182F 3-48 Honeywell R8184G, K, L, N Cad Cell Relay 3-49 Honeywell R8184M, P 3-49 Honeywell R8285D 3-50 Riello Model 40F5 3-51 Fireye Flame Safeguard Controls General Instructions 3-52 CHS or CHW with: 24CJ5, Model 3010, 3011 3-53 24CU6, Model 1062, 1063 3-54 24CF6, Model 1010, 1011 3-55 25CU6, Model 5056 3-56 26CF6, Model 5023 3-57 24CJ5, Model 5015 3-58 25CU6 Model 3010, 3011 3-59 26CF6 Model 5022 3-60 EP (D)160, EP161, EP(D)170 3-61 Modular M Series 3-62 3/6/2006

UVM-1 3-63 UVM-1D, 1F, 2A, 3 or TFM -1D, 1F, 2A, 3 3-64 UVM-2A or TFM-2A 3-65 UVM-3 or TFM-3 3-66 LCH or LCS with: 24CJ5, Model 3010, 3011 3-67 24CU6, Model 1062, 1063 3-68 26CF6, Model 1010, 1011 3-69 25CU6, Model 5066 3-70 25CF6, Model 5023 3-71 24CJ5 Model 5015 3-72 25CU6 Model 5065 3-73 26CF6, Model 5022 3-74 EP (D)160, EP161, EP(D)170 3-75 Modular M Series 3-76 UVM-1 3-77 UVM-1D, 1F, 2A, 3 or TFM -1D, 1F, 2A, 3 3-78 UVM-2A or TFM-2A 3-79 UVM-3 or TFM-3 3-80 Honeywell Flame Safeguard Controls General Instructions 3-81 CHS or CHW with: R4140G, L, M or R4150A, C, X 3-82 R4795A, D 3-83 R7795A, B, C, D 3-84 RM7800 or RM7840E, G, L, M 3-85 LCH with: AO Smith DuraMax Models DB/DW 720-1810 3-86 LCH or LCS with: R890E, F, G 3-87 R4140G, L, M or R4150A, C, X 3-88 R4795A, D 3-89 R7795A, B, C, D 3-90 RM7800 or RM7840E, G, L, M 3-91 RM 7895 3-92 Refrigeration RU Wiring Precautions 4-1 RU Wiring Diagrams 4-2 3/6/2006

Pressure Control Operated, 115vac power/control 4-2 Pressure Control Operated, 220vac power/ control 4-3 Pump-down System, 220vac power/control 4-5 Pump-down System, 220vac power/24vac control 4-6 Pump-down System, 220vac power/115vac control 4-7 FA/CFA FA with Honeywell R8184G, K, L or N Cad Cell Relay 5-1 FA with Honeywell R8184 M or P Cad Cell Relay 5-1 FA with Honeywell R7184A, B, P, U Electronic Oil Primary 5-2 FA with Honeywell R7184A, B, P, U Series 5 Relay 5-3 FA with Typical Residential Warm Air Furnace 5-4 FA with Riello Burner and Relay Module 5-5 CFA with Typical Packaged HVAC Unit 5-6 6 3/21/2007

AIR CONDITIONING CAUTION: Read and follow these general instructions and the instructions that are packed with the IntelliCon Model AC or CAC. Failure to follow these instructions could result in damage to the system or cause a hazardous condition. General Instructions: The IntelliCon Models AC and CAC are connected in the control circuit so that the call for the compressor to run is interrupted between the thermostat and the compressor. These connections are at the Y terminals on the unit low voltage control connection board. These connections are made as follows: 1. Remove the compressor call wire from the Y terminal. 2. Connect the IntelliCon wire to this wire with a wire nut. 3. Connect the IntelliCon wire to the Y terminal. The IntelliCon Economizer is now connected in the control circuit in series after the thermostat but before any and all safety controls and the compressor. Two Stage Air Cooled Air Conditioning Systems; Some two stage cooling systems are designed to have the condenser fan energized with the first stage compressor, while the second condenser fan is energized on outdoor air temperature or condenser coil temperature. When the IntelliCon CAC is in the Economizing mode delaying the first stage compressor, the second stage compressor could be energized leaving it to run without the condenser fan running. This could result in the second stage cooling locking out on high pressure safety and not available for cooling when needed. This is corrected by wiring the second stage compressor contactor to the first stage condenser fan relay. Be sure to check electrical voltage and phasing. After mounting and wiring, test the operation of the IntelliCon CAC and condenser fans before leaving the installation. Continued on next page 5/31/2006 1

HEAT PUMP UNITS (All Manufacturers) On most systems the IntelliCon AC or CAC units can be wired into the 24vac control circuit at the Y terminal in the air handler. When wired this way, the AC or CAC is in the circuit when in the cooling mode or heating mode. It is extremely important to be sure that the system you are installing on is wired this way. Connect the AC or CAC as you normally would at the Y terminal. York Heat Pumps: Older York Heat Pump systems were wired so that the thermostat opened the 24vac COMMON instead of the 24vac HOT. To connect the IntelliCon Economizers in the 24vac control circuit, the IntelliCon wire must be connected to the 24vac HOT. This is because the thermostat compressor wire is the 24vac COMMON instead of the normal 24vac HOT. 2-2 3/06/06

IntelliCon CAC with Typical Packaged HVAC Unit L1 L2 L3 Single or Three Phase Line Power Supply Unit Control Transformer DWG# DATE: DATE From Thermostat IntelliCon CAC TAPE OFF R C G W Y 3/06/06 2-3

IntelliCon AC or CAC with Typical 24vac Power To IntelliCon AIR HANDLING UNIT Low Voltage Terminal Board Air Handling Unit TAPE OFF R C G Y W IntelliCon To Condensing Section DWG# DATE: DATE Unit Transformer 230vac/24vac R C L1 L2 To T-Stat 208/230 vac 1 Phase L1 L2 208/230vac Power To IntelliCon AIR HANDLING UNIT TAPE OFF IntelliCon Low Voltage Terminal Board R C G Y W To Condensing Section Unit Transformer 230vac/24vac R L1 C L2 To T-Stat 208/230 vac 1 Phase L1 L2 2-4 3/06/06

IntelliCon AC or CAC with Typical Outdoor Condensing Section IntelliCon TAPE OFF DWG# DATE: DATE 24vac From Thermostat Y C COMPRESSOR CONTACTOR L2 L1 208/230 vac 1 Phase L1 L2 HIGH PRESSURE SWITCH LOW PRESSURE SWITCH T1 T2 TO COMPRESSOR TYPICAL OUTDOOR CONDENSING SECTION 3/06/06 2-5

Trane Units: With Honeywell W973 Logic Panel Units with Honeywell W973 Logic Panel installed CANNOT have the IntelliCon CAC Economizer wired at the compressor contactor. A low pressure bypass timer is in series in the safety control circuit with the high pressure safety switch, low pressure safety switch, etc. that will cause the compressor to lockout on a reset relay if the compressor does not start immediately upon the call for cooling from the W973 Logic Panel. The low voltage terminal board in these units also cannot be used because it is 20 volts DC. To connect the IntelliCon CAC Economizer to systems using the Honeywell W973 Logic Panel, follow the factory authorized directions below and the wiring diagrams following pages. The IntelliCon CAC module can be wired at COOL 1 of the W973. 1. Remove the wire from the load side of the NORMALLY OPEN contact of COOL 1 2. Connect the wire to this wire and connect the wire to the NORMALLY OPEN contact of COOL 1 Properly connected, upon a ramping of the DC Voltage at the W973 from the Space Transmitter, Cool 1 will energize but will be routed through the IntelliCon CAC first. 2-6 3/06/06

Honeywell W973 Logic Panel Using 24vac Control Circuit TAPE OFF R IntelliCon CAC DWG# DATE: DATE W973 LOGIC PANEL 2 HEAT 1 3 HEAT 3 COOL 2 COOL 1 WH MOD - HEAT BH RH RC MOD - COOL BC WC SENSOR C STAT +20 H N 24VAC ECONO R C T T1 3 4 2 5 1 TR TR W B Y R UNIT TRANSFORMER TO 24vac COMPRESSOR CIRCUIT L1 L2 120VAC POWER N H 3/06/06 2-7

Honeywell W973 Logic Panel Using 120vac Control Circuit TAPE OFF R IntelliCon CAC DWG# DATE: DATE W973 LOGIC PANEL 2 HEAT 1 3 HEAT 3 COOL 2 COOL 1 WH MOD - HEAT BH RH RC MOD - COOL BC WC SENSOR C STAT +20 H N 24VAC ECONO T T1 3 4 2 5 1 TR TR W B Y R 120VAC POWER N H TO 120vac COMPRESSOR CIRCUIT 2-8 3/06/06

TRANE VOYAGER WITH THERMOSTAT INTERFACE BOARD These units utilize a normal electronic or electro-mechanical thermostat. Connect the IntelliCon CAC to the Low Voltage Terminal Board in the Trane unit as follows: IMPORTANT; The following directions represent only one of the many variations of the Low Voltage Wiring Schematic supplied with the Trane Thermostat Interface Board due to changes in the Trane Voyager unit. CONSULT THE UNITS THERMOSTAT INTERFACE BOARD WIRING DIAGRAM FOR THE PROPER TERMINALS. 1. Remove the thermostat Y1 wire from terminal on the low voltage terminal board (LTB). 2. Connect the wire from the IntelliCon CAC to the wire you just removed. 3. Connect the wire from the IntelliCon to the terminal where you removed the Y1 wire from the thermostat on the low voltage terminal board (LTB). 3/06/06 2-9

Trane VOYAGER WITHOUT THERMOSTAT INTERFACE BOARD These units CANNOT have the IntelliCon CAC wired at the low voltage terminal board. Without the Thermostat Interface Board, a Trane ZONE SENSOR is used instead of a conventional thermostat and utilizes a DC voltage ramp. The IntelliCon CAC MUST be wired at compressor #1 contactor as shown in the diagram. Follow the same directions if the unit has 2 compressors. Figure A shows the factory wiring of compressor #1 contactor. Figure B shows how to wire in the IntelliCon CAC using a 200 ohm, 10 watt resistor. This resistor must be used to complete a voltage circuit back to the UPC board or the UPC board will lock the compressor out, requiring a manual reset of the unit. To connect the IntelliCon CAC to this configuration use the wiring diagrams on the following page. 2-10 3/06/06

Fig. A Fig. B IntelliCon 3/06/06 2-11

Beckett HeatManager with Honeywell L7124A,C or L7148A Oil Electronic Aquastat HeatManager TAPE OFF DWG# DATE: DATE L1 L2 T T 120 H VAC N TYPICAL HONEYWELL L7124A,C or L7148A C1 ZC B2 C2 ZR B1 To Line Voltage Oil Burner Relay 3/06/06 3-1

Beckett HeatManager with Honeywell L7124U Universal Oil Electronic Aquastat HeatManager TAPE OFF DWG# DATE: DATE L1 L2 T T 120 H VAC N TYPICAL HONEYWELL L7124U C1 ZC B2 C2 ZR B1 To Line Voltage Oil Burner Relay 3-2 3/06/06

Beckett HeatManager with Honeywell L7148F TAPE OFF HeatManager Electronic Aquastat 120 VAC To 24vac Burner Control DWG# DATE: DATE R C C R S1 S2 L2 L1 B2 H C1 G L2X TYPICAL HONEYWELL L7148F N B1 R L1X L1 C2 L2 NOTE: Not All Terminals Shown To Boiler Sensor 3/06/06 3-3

Beckett HeatManager with Honeywell L7224U Oil Electronic Aquastat Controller T HeatManager TAPE OFF T 3 DATE: 2 1 ZR L1 L2 TYPICAL C2 L7224U (Not All B2 Terminals And Wiring C1 Shown) B1 ZC TO LINE VOLTAGE OIL BURNER RELAY 3-4

Beckett HeatManager with Honeywell L8124A,C HeatManager TAPE OFF DWG# DATE: 120VAC L1 L2 T T G TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE TYPICAL HONEYWELL L8124A,C C1 ZR B2 C2 ZR B1 BREAK CONNECTION HERE 3/06/2006 3-5

3-6 Beckett HeatManager with Honeywell L8124E HeatManager TAPE OFF DWG# DATE: DATE TV T Z TYPICAL HONEYWELL L8124E C1 C2 B1 B2 L1 L2 G TO 24VAC GAS VALVE H N G 120VAC

Beckett HeatManager with Honeywell L8124G,L HeatManager TAPE OFF DWG# DATE: DATE TV T Z TYPICAL HONEYWELL L8124G,L B2 B1 C2 C1 L1 L2 G TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE H N G 120VAC 3/06/06 3-7

Beckett HeatManager with Honeywell L8148A HeatManager TAPE OFF DWG# DATE: DATE G L1 L2 T T 120 VAC G H N TYPICAL HONEYWELL L8148A C1 C2 B1 B2 TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE 3-8 3/06/2006

Beckett HeatManager with Honeywell L8148E HeatManager TAPE OFF DWG# DATE: DATE TV W T Z TYPICAL HONEYWELL L8148E C1 C2 B1 B2 L1 L2 TO 24VAC GAS VALVE H N 120VAC 3/06/06 3-9

Beckett HeatManager with Honeywell L8148J HeatManager TAPE OFF DWG# DATE: DATE TV W T TP Z TYPICAL HONEYWELL L8148J C1 C2 B1 B2 B3 L1 L2 G TO 24VAC GAS VALVE H N G 120VAC 3-10 3/06/06

Beckett HeatManager with Honeywell L8151A HeatManager TAPE OFF DWG# DATE: DATE G L1 L2 T T 120 G VAC H N TYPICAL HONEYWELL L8151A C1 ZC B2 C2 ZR B1 TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE 3/06/06 3-11

Beckett HeatManager with Honeywell R7184A,B,P,U L1 Electronic Oil Primary HeatManager THERMOSTAT CIRCULATOR PUMP DWG# DATE: DATE C1 TYPICAL HONEYWELL R7184 B2 B1 120vac C2 L2 AQUASTAT CONTROLLER TAPE OFF R T W T T LIMIT T L1 L2 NOTE: Not All Terminals Shown CAD CELL BURNER MOTOR IGNITOR VALVE 3-12 3/06/06

Beckett HeatManager with Honeywell R7184A,B,P,U Electronic Oil Primary When Aquastat Is Wired 24VAC TAPE OFF HeatManager Diagram "C" Typical Honeywell L4006A Aqustat DWG# DATE: DATE CONSTANT 120 VAC T T NOTE: In this application the wire MUST be used instead of the wire. IGNITOR Typical Honeywell R7184 SIDE VIEW Diagnostic Light Red Reset Button Data Port Burner Motor L1 L2 LIMIT VALVE Typical Honeywell R7184 BOTTOM VIEW May Require A Piggyback Connector CAD CELL 3-13

Beckett HeatManager with Honeywell R7184A,B,P,U "SERIES 5" Electronic Oil Primary When Aquastat Is Wired 24VAC TAPE OR WIRENUT Typical Honeywell R7184 SIDE VIEW Diagnostic Light DWG# DATE: DATE Data Port Red Reset Button 1 Typical Honeywell L4006A Aqustat CONSTANT 120 VAC HeatManager Delay Time Dip Switch Alarm Terminals EnviroCom Terminals 2 Thermostat Terminals T R7184A,B,P,U 5 R7184A1075 T 3 3-14 3/06/06

Beckett HeatManager with Honeywell R8182D HeatManager Blue Tape Off Individually DWG# DATE: DATE Grey INSTRUCTIONS Violet White Remove the existing Yellow wire from the bottom of the HI Limit Setting switch. Insert the HeatManager "" wire into the wire hole. Connect the HeatManager "" wire to the Yellow wire that was removed. Black 120 H VAC N L1 Brown L2 B B T T DIF Safety Switch Reset Button H I L O Circuit Board ZR Yellow Red F F B1 ZC C1 B2 C2 Yellow wire from bottom of HI Limit Setting 3/06/06 3-15

Beckett HeatManager with Honeywell R8182E HeatManager Blue Tape Off Individually DWG# DATE: DATE Grey INSTRUCTIONS Violet White Remove the Yellow wire from the bottom terminal of the Aquastat Switch. Connect the HeatManager "" wire to this terminal. Connect the HeatManager "" wire to the Yellow wire that was removed Black 120 H VAC N L1 Brown L2 T T Safety Switch Reset Button Aquastat Switch Circuit Board ZR Yellow ZC Red F F B1 C1 B2 C2 Yellow wire from bottom of Aquastat Switch 3-16 3/06/06

Beckett HeatManager with Honeywell R8182F HeatManager Blue Tape Off Individually DWG# DATE: DATE Grey INSTRUCTIONS Violet White Remove the existing wire from the bottom of the HI Limit Setting switch. Insert the HeatManager "" wire into the wire hole. Connect the HeatManager"" wire to the Yellow wire that was removed. Black 120 H VAC N L1 Brown L2 B B T T Aquastat Switch Safety Switch Reset Button H I L O Circuit Board Yellow Red F F B1 C1 B2 C2 Wire from bottom of HI Limit Setting 3/06/06 3-17

HeatManager HeatManager DIAGRAM "A" DIAGRAM "B" Beckett HeatManager with Honeywell Beckett HeatManager with Honeywell R8184G, K, L or N Cad Cell Relay R8184M or P Cad Cell Relay TAPE OFF TAPE OFF OPERATING AQUASTAT T R ORANGE TYPICAL HONEYWELL R8184G,K,L or M T ORANGE TYPICAL HONEYWELL R8184M, P W C Y G 120VAC F F CAD CELL EYE 120VAC F F CAD CELL EYE DWG# DATE: DATE 3-18 3/06/06

Beckett HeatManager With Honeywell R8285D Relay/Transformer Package When Used On Boilers DWG# DATE: DATE L1 L2 120/60/1 Power Supply Fused Disconnect Switch Service Switch 1 3 Primary Circulator Motor 24V Transformer R C Secondary THERMOSTAT G COIL Damper 1K-2 1 1 4 4 Motor 4 6 Y High Limit 5 1K-1 2 R C NC 1K-3 3 2 W NO TH TR FRS BVS BREAK CONNECTION HERE HeatManager TAPE OFF 3-19

Beckett HeatManager with Riello 40F5 Burner (if experiencing voltage feedback from burner on IntelliCon "" Wire) 120VAC POWER N H Electronic OR Mechanical TAPE OFF DWG# DATE: DATE Operating Aquastat Addiitional Wire Added For Electronic Shutter AUX REILLO L BURNER N HeatManager Field Supplied 120VAC Coil Single Pole SingleThrow Relay 3-20 3/06/06

Wiring the IntelliCon HW or LCH with A Cad Cell Relay A boiler with the operating limit control (aqua-stat) wired to T T on the cad cell relay does not have to be rewired to accommodate the installation of the Model HW or LCH even though the internal transformer of the cad cell relay is not accessible for 24vac control wiring purposes. DO NOT connect the HW or LCH control circuit at the orange lead on the cad cell relay as the burner will go off on safety. Wiring the HW or LCH control circuit at the black lead of the cad cell relay will remove power to the cad cell relay transformer. If the TT terminals have a jumper across them, then the operating aqua-stat is line voltage and the HW or LCH can be wired 115vac for the power and the control circuit. Below are the factory authorized wiring diagrams to accomplish the installation: Diagram A : Honeywell R8184 G, K, L, N Diagram B : Honeywell R8184 M, P Diagram C : Honeywell R7184 A, B, P, U Diagram D : Honeywell R7184 A, B, P, U, REVISION 5 3/06/06 3-21

IntelliCon HW IntelliCon HW DIAGRAM "A" DIAGRAM "B" IntelliCon HW with Honeywell IntelliCon HW with Honeywell R8184G, K, L or N Cad Cell Relay R8184M or P Cad Cell Relay TAPE OFF TAPE OFF OPERATING AQUASTAT T R ORANGE TYPICAL HONEYWELL R8184G,K,L or M T ORANGE TYPICAL HONEYWELL R8184M, P W C Y G 120VAC F F CAD CELL EYE 120VAC F F CAD CELL EYE DWG# DATE: DATE 3-22 3/06/06

IntelliCon HW LCH, LCS with Honeywell R7184A,B,P,U Electronic Oil Primary When Aquastat Is Wired 24VAC TAPE OFF CONSTANT 120 VAC DWG# DATE: DATE IntelliCon R Diagram "C" Typical Honeywell L4006A Aqustat T T IGNITOR Typical Honeywell R7184 SIDE VIEW Diagnostic Light Red Reset Button Data Port Burner Motor L1 L2 LIMIT VALVE May Require A Piggyback Connector Typical Honeywell R7184 BOTTOM VIEW CAD CELL 3/06/06 3-23

IntelliCon HW, LCH, LCS with Honeywell R7184A,B,P,U "SERIES 5" Electronic Oil Primary When Aquastat Is Wired 24VAC TAPE OR WIRENUT CONSTANT 120 VAC DWG# DATE: DATE IntelliCon R Typical Honeywell R7184 SIDE VIEW Diagnostic Light Data Port Red Reset Button Delay Time Dip Switch EnviroCom Terminals Alarm Terminals Thermostat Terminals T 1 2 Typical Honeywell L4006A Aqustat 3 T Diagram "D" 3-24 3/06/06

3-25

3-26

HEAT TIMER Rewire With Jumper As Shown IntelliCon LCH With Mechanical "Heat Timer" (With Internal Domestic Hot Water Coil) HOT GND 115 V 115 V B B C C T T 115 VAC N H DWG# DATE: DATE IntelliCon LCH Splitter Yellow Black Remove Wires From From "B" and "B" Terminals And Rewire As Shown NOTE: Center Pins MUST BE REMOVED From This Plug W R Original Wires From "B" and "B" Terminals Field Supplied Double Pole, Double Throw Relay With 120vac Coil Going To Burner Control Circuit NEW WIRING L6006C1018 OR EQUIVILANT STRAP-ON AQUASTAT USE N.O. CONTACTS NEW WIRING Domestic Sensor Supply Sensor 3/06/06 3-27

HEAT TIMER Model "MPC" IntelliCon LCH With Heat Timer Model "MPC" (With Internal Domestic Hot Water Coil) IntelliCon LCH DWG# DATE: DATE Splitter NOTE: Center Pins MUST BE REMOVED From This Plug Yellow Black NEW WIRING 115 VAC 1 2 3 4 5 6 7 8 9 H N NOTE: Not All Terminals Are Shown R W L6006C1018 OR EQUIVILANT STRAP-ON AQUASTAT USE N.O. CONTACTS Supply Temperature Sensor Domestic Sensor 3-28 3/06/06

HEAT TIMER Rewire With Jumper As Shown IntelliCon LCS With Mechanical "Heat Timer" (With Internal Domestic Hot Water Coil) HOT GND 115 V 115 V B B C C T T 115 VAC N H DWG# DATE: DATE IntelliCon LCS Yellow Black Remove Wires From From "B" and "B" Terminals And Rewire As Shown Splitter NOTE: Center Pins MUST BE REMOVED From This Plug W Field Supplied Double Pole, Double Throw Relay Original Wires From "B" and "B" Terminals With 120vac Coil Going To Burner Control Circuit NEW WIRING R L6006C1018 NEW WIRING OR EQUIVILANT STRAP-ON AQUASTAT USE N.O. CONTACTS Domestic Sensor Steam Pressure Sensor 3/06/06 3-29

HEAT TIMER Model "MPC" IntelliCon LCS With Heat Timer Model "MPC" (With Internal Domestic Hot Water Coil) IntelliCon LCS DWG# DATE: DATE Splitter NOTE: Center Pins MUST BE REMOVED From This Plug Yellow Black NEW WIRING 115 VAC 1 2 3 4 5 6 7 8 9 H N NOTE: Not All Terminals Are Shown R W L6006C1018 OR EQUIVILANT STRAP-ON AQUASTAT USE N.O. CONTACTS Steam Pressure Sensor Domestic Sensor 3-30 3/06/06

IntelliCon HW with Riello 40F5 Burner (if experiencing voltage feedback from burner on IntelliCon "" Wire) TAPE OFF Addiitional Wire Added For Electronic Shutter AUX REILLO DWG# DATE: DATE IntelliCon HW 120VAC POWER N H Electronic OR Field Supplied 120VAC Coil Single Pole SingleThrow Relay R L BURNER N Mechanical Operating Aquastat 3/06/06 3-31

IntelliCon HW with Honeywell L7124A,C or L7148A Oil Electronic Aquastat IntelliCon HW TAPE OFF DWG# DATE: DATE L1 L2 T T 120 H VAC N TYPICAL HONEYWELL L7124A,C or L7148A C1 ZC B2 C2 ZR B1 To Line Voltage Oil Burner Relay 3-32 3/06/06

IntelliCon HW with Honeywell L7124U Universal Oil Electronic Aquastat IntelliCon HW TAPE OFF DWG# DATE: DATE L1 L2 T T 120 H VAC N TYPICAL HONEYWELL L7124U C1 ZC B2 C2 ZR B1 To Line Voltage Oil Burner Relay 3/06/06 3-33

IntelliCon HW with Honeywell L7148F Electronic Aquastat TAPE OFF To 24vac Burner Control DWG# DATE: DATE IntelliCon HW 120 VAC R C C R S1 S2 L2 L1 H B2 N C1 G L2X B1 TYPICAL HONEYWELL L7148F R L1X L1 C2 L2 NOTE: Not All Terminals Shown To Boiler Sensor 3-34 3/06/06

IntelliCon HW with Honeywell L7224U Oil Electronic Aquastat Controller T T 3 IntelliCon HW 2 TAPE OFF TO LINE DATE: VOLTAGE OIL BURNER RELAY 1 ZR L1 L2 TYPICAL C2 L7224U (Not All B2 Terminals And Wiring C1 Shown) B1 ZC 3/06/06 3-35

IntelliCon HW with Honeywell L8124A,C IntelliCon HW R TAPE OFF DWG# DATE: 120VAC L1 L2 T T G TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE TYPICAL HONEYWELL L8124A,C C1 ZR B2 C2 ZR B1 BREAK CONNECTION HERE 3-36 3/06/06

IntelliCon HW with HONEYWELL L8124E IntelliCon HW TAPE OFF DWG# DATE: DATE TV T Z TYPICAL HONEYWELL L8124E C1 C2 B1 B2 L1 L2 G TO 24VAC GAS VALVE H N G 120VAC 3/06/06 3-37

IntelliCon HW with Honeywell L8124G,L IntelliCon HW TAPE OFF DWG# DATE: DATE TV T Z TYPICAL HONEYWELL L8124G,L B1 B2 C2 C1 L1 L2 G TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE H N G 120VAC 3-38 3/06/06

IntelliCon HW with Honeywell L8148A IntelliCon HW TAPE OFF DWG# DATE: DATE G L1 L2 T T 120 VAC G H N TYPICAL HONEYWELL L8148A C1 C2 B1 B2 TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE 3/06/06 3-39

IntelliCon HW with Honeywell L8148E IntelliCon HW TAPE OFF DWG# DATE: DATE TV W T Z TYPICAL HONEYWELL L8148E C1 C2 B1 B2 L1 L2 TO 24VAC GAS VALVE H N 120VAC 3-40 3/06/06

IntelliCon HW with Honeywell L8148J IntelliCon HW TAPE OFF DWG# DATE: DATE TV W T TP Z TYPICAL HONEYWELL L8148J C1 C2 B1 B2 B3 L1 L2 G TO 24VAC GAS VALVE H N G 120VAC 3-41

IntelliCon HW with Honeywell L8151A IntelliCon HW TAPE OFF DWG# DATE: DATE G L1 L2 T T 120 VAC G H N TYPICAL HONEYWELL L8151A C1 ZC B2 C2 ZR B1 TO LINE VOLTAGE OIL BURNER RELAY OR GAS VALVE 3-42 3/06/06

IntelliCon HW with Honeywell R7184A,B,P,U Electronic Oil Primary IntelliCon HW THERMOSTAT CIRCULATOR PUMP C1 C2 AQUASTAT CONTROLLER R T DWG# DATE: DATE W T T LIMIT TYPICAL HONEYWELL R7184 B2 B1 L1 L2 TAPE OFF T L1 L2 NOTE: Not All Terminals Shown BURNER MOTOR CAD CELL 120vac IGNITOR VALVE 3/06/06 3-43

IntelliCon HW with Honeywell R7184A,B,P,U "SERIES 5" Electronic Oil Primary When Aquastat Is Wired 24VAC TAPE OR WIRENUT CONSTANT 120 VAC DWG# DATE: DATE IntelliCon HW Typical Honeywell R7184 SIDE VIEW Typical Honeywell L4006A Aqustat Diagnostic Light Data Port Red Reset Button Thermostat Terminals T T 3 Delay Time Dip Switch EnviroCom Terminals 2 Alarm Terminals 1 3-44 3/06/06

IntelliCon HW with Honeywell R8182D IntelliCon HW Blue Tape Off Individually DWG# DATE: DATE Grey INSTRUCTIONS Violet White Remove the existing Yellow wire from the bottom of the HI Limit Setting switch. Insert the HeatManager "" wire into the wire hole. Connect the HeatManager "" wire to the Yellow wire that was removed. Black 120 H VAC N L1 Brown L2 B B T T DIF Safety Switch Reset Button H I L O Circuit Board ZR Yellow Red F F B1 ZC C1 B2 C2 Yellow wire from bottom of HI Limit Setting 3-46 3/06/06

IntelliCon HW with Honeywell R8182E IntelliCon HW Blue Tape Off Individually DWG# DATE: DATE Grey INSTRUCTIONS Violet White Remove the Yellow wire from the bottom terminal of the Aquastat Switch. Connect the HeatManager "" wire to this terminal. Connect the HeatManager "" wire to the Yellow wire that was removed Black 120 H VAC N L1 Brown L2 T T Safety Switch Reset Button Aquastat Switch Circuit Board ZR Yellow Red F F B1 ZC C1 B2 C2 Yellow wire from bottom of Aquastat Switch 3/06/06 3-47

IntelliCon HW with Honeywell R8182F IntelliCon HW Blue Tape Off Individually DWG# DATE: DATE Grey INSTRUCTIONS Violet White Remove the existing wire from the bottom of the HI Limit Setting switch. Insert the HeatManager "" wire into the wire hole. Connect the HeatManager"" wire to the Yellow wire that was removed. Black 120 H VAC N L1 Brown L2 B B T T Safety Switch Reset Button H I L O Circuit Board Yellow Red F F B1 C1 B2 C2 Wire from bottom of HI Limit Setting 3-48 3/06/06

IntelliCon HW With Honeywell R8285D Relay/Transformer Package When Used On Boilers DWG# DATE: DATE L1 L2 120/60/1 Power Supply Fused Disconnect Switch Service Switch 1 3 Primary Circulator Motor 24V Transformer R C Secondary THERMOSTAT G COIL Damper 1K-2 1 1 4 4 Motor 4 6 Y High Limit 5 1K-1 2 R C NC 1K-3 3 2 W NO TH TR FRS BVS BREAK CONNECTION HERE IntelliCon HW TAPE OFF 3-50 3/06/06

Fireye Flame Safeguard Controls General Instructions The IntelliCon Heating Economizers are connected in series in the burner control circuit AFTER the operating safety s and limit controls and BEFORE the burner Flame Safeguard Primary Control. ***ATTENTION MUST BE GIVEN WHEN A DRAFT INDUCER IS USED ON THE BOILER*** *** When a draft inducer is being used, the operating limit control, on closure, will activate a relay, contactor or starter to enable the draft inducer. An air proving switch will close indicating that the draft inducer is running and a negative air flow has been established through the boiler. Once the negative airflow has been established the Flame Safeguard is enabled and starts the burner sequence. Improperly connected into the operating limit circuit, the draft inducer will run drawing ambient (or cooler) air through the boiler while the IntelliCon Heating Economizer is in the ECONOMY mode. Each installation should be checked for the proper connection point of the IntelliCon Heating Economizer. The following wiring diagrams show the connection points of the IntelliCon Heating Economizer at the Fireye Flame Safeguard ONLY. If a draft inducer is used as explained above, determine the connection point from the operating limit control BEFORE the Flame Safeguard Control. 3-52

IntelliCon CHS or CHW With Fireye DATE: 3 M 5 L1 A P S1 7 S2 L2 TYPICAL FIREYE 24CJ5, 25CU6, 26CF6 120VAC POWER H N 24CJ6 Model 3010, 3011 24CU6 Model 1062, 1063 24CF6 Model 1010, 1011 IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS NOTE: Add jumper as shown between terminals "115/220" and "COMMON" Original Limits Burner Motor Ignition Alarm Interlocks To Flame Detector Main Fuel Valve Note: Not all terminals shown. LIMIT CONTROL 24 115/220 CALL BURNER 220 115 24 COMMON COMMON SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW 3/06/06 3-53

IntelliCon CHS or CHW With Fireye 25CU6 Model 5066 26CF6 Model 5023 24CJ5 Model 5015 IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW NOTE: Add jumper as shown between terminals "115/230" and "COMMON" DATE: Original Limits 13 M 5 L1 Burner Motor Ignition A P Alarm Interlocks To Flame Detector S1 7 Main Fuel Valve S2 L2 TYPICAL FIREYE 25CU6, 26CF6, 24CJ5 Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N 24 115/220 CALL BURNER 220 115 24 COMMON COMMON 3-56 3/06/06

IntelliCon CHS or CHW With Fireye 25CU6 Model 3010, 3011 26CF6 Model 5022 IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW NOTE: Add jumper as shown between terminals "115/230" and "COMMON" DATE: Original Limits Burner Motor 13 M 5 L1 Ignition A P Alarm Interlocks To Flame Detector S1 7 S2 Main Fuel Valve Note: Not all terminals shown. L2 TYPICAL FIREYE 25CU6, 26CF6 LIMIT CONTROL 120VAC POWER H N 24 115/220 CALL BURNER 220 115 24 COMMON COMMON 3/06/06 3-59

IntelliCon CHS or CHW With Fireye EP (D) 160 EP 161 EP (D) 170 Flame Monitors IntelliCon Wiring Compartment FUTURE BURNER CONTROL USE CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SENSOR CONNECTORS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. S/W SW NOTE: Add jumper as shown between terminals "115/230" and "COMMON" Original DATE: Limits Burner Motor 13 M 4 L1 Ignition To Flame Scanner Alarm A S1 3 7 Pilot Valve S2 Main Fuel Note: Not all terminals shown. L2 TYPICAL FIREYE E- Series LIMIT CONTROL 120VAC POWER H N 115/220 BURNER 115 COMMON 24 CALL 220 24 COMMON 3/06/06 3-61

IntelliCon CHS or CHW With Fireye Modular M Series IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW NOTE: Add jumper as shown between terminals "115/230" and "COMMON" DATE: Original Limits Burner Motor 7 8 4 1 Ignition A 6 To Flame Scanner Alarm S1 3 Pilot Valve S2 Main Fuel TYPICAL FIREYE Micro-M Note: Not all terminals shown. 2 LIMIT CONTROL 120VAC POWER H N 24 115/220 CALL BURNER 220 115 24 COMMON COMMON 3-62 3/06/06

IntelliCon CHS or CHW With Fireye UVM - 1 IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW NOTE: Add jumper as shown between terminals "115/230" and "COMMON" DATE: Original Limits Burner Motor 1 3 4 5 Main Fuel Ignition A S T-Stat or Operating Control Alarm T S T 2 TYPICAL FIREYE UVM-1 Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N 24 115/220 CALL BURNER 220 115 24 COMMON COMMON 3/06/06 3-63

IntelliCon CHS or CHW With FIREYE UVM-1D, 1F, 2A, 3 TFM-1D,1F, 2A, 3 IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW NOTE: Add jumper as shown between terminals "115/230" and "COMMON" DATE: Original Limits Burner Motor 7 8 4 1 Ignition A 6 To Flame Detector Alarm S1 Air Flow Switch 3 S2 No 1 Oil Valve TYPICAL FIREYE UVM, TFM Note: Not all terminals shown. 2 LIMIT CONTROL (Not Used On TFM Models) 120VAC POWER H N 24 115/220 CALL BURNER 220 115 24 COMMON COMMON 3-64 3/06/06

IntelliCon CHS or CHW With FIREYE UVM-2A and TFM-2A IntelliCon Wiring Compartment FUTURE BURNER CONTROL USE CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW Add jumper as shown between terminals "115/230" and "COMMON" DATE: Original Limits Burner Motor 7 8 4 1 Ignition A 6 To Flame Detector Alarm S1 Air Flow Switch 3 S2 No 1 Oil Valve/Pilot Gas Valve TYPICAL FIREYE UVM, TFM Note: Not all terminals shown. 2 LIMIT CONTROL 120VAC POWER H N 24 115/220 CALL BURNER 220 115 24 COMMON COMMON 3/06/06 3-65

IntelliCon CHS or CHW With FIREYE UVM-3 and TFM-3 IntelliCon Wiring Compartment FUTURE BURNER CONTROL USE CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SENSOR CONNECTORS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. S/W SW NOTE: Add jumper as shown between terminals "115/230" and "COMMON" Original DATE: Limits Burner Motor 7 8 4 1 Ignition A 6 To Flame Detector Alarm S1 Air Flow Switch 3 S2 No 1 Oil Valve/Pilot Gas Valve TYPICAL FIREYE UVM, TFM Note: Not all terminals shown. 2 LIMIT CONTROL (Not Used On TFM Models) 120VAC POWER H N 115/220 BURNER 115 COMMON 24 CALL 220 24 COMMON 3-66 3/06/06

IntelliCon LCH or LCS With FIREYE 24CJ5 Model 3010, 3011 25CU6 Model 1062,1063 26CF6 Model 1010, 1011 IntelliCon Original TAPE OFF To Flame Detector LIMIT CONTROL DATE: 3 L1 Limits Burner Motor M 5 Ignition Alarm A P Interlocks S1 7 S2 Main Fuel Valve L2 TYPICAL FIREYE 24CJ5, 25CU6, 26CF6 Note: Not all terminals shown. 120VAC POWER H N 3/06/06 3-67

IntelliCon LCH or LCS With FIREYE 25CU6 Model 5066 26CF6 Model 5023 24CJ5 Model 5015 IntelliCon Original TAPE OFF To Flame Detector LIMIT CONTROL DATE: 13 L1 Limits Burner Motor M 5 Ignition Alarm A P Interlocks S1 7 S2 Main Fuel Valve L2 TYPICAL FIREYE 25CU6, 26CF6, 24CJ5 Note: Not all terminals shown. 120VAC POWER H N 3-70 3/06/06

IntelliCon LCH or LCS With FIREYE 25CU6 Model 5065 26CF6 Model 5022 TAPE OFF IntelliCon Original To Flame Detector DATE: 13 L1 Limits Burner Motor M 5 Ignition A P Alarm Interlocks S1 7 S2 Main Fuel Valve L2 TYPICAL FIREYE 25CU6, 26CF6 Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N 3/06/06 3-73

IntelliCon LCH or LCS With FIREYE EP(D)160 EP161 EP(D)170 Flame Monitors IntelliCon Original TAPE OFF To Flame Scanner DATE: 13 L1 Limits Burner Motor M 4 Ignition A 3 Lockout Alarm Pilot Valve S1 7 Main Fuel S2 L2 TYPICAL FIREYE E-Series Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N 3/06/06 3-75

IntelliCon LCH or LCS With FIREYE Modular M Series IntelliCon Original TAPE OFF To Flame Scanner DATE: 7 1 Limits Burner Motor 8 4 Ignition Alarm A 3 Pilot Valve S1 5 Main Fuel S2 2 TYPICAL FIREYE Micro-M Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N 3-76 3/06/06

IntelliCon LCH or LCS With FIREYE UVM-1 IntelliCon Original TAPE OFF T-Stat or Operating Control 1 5 Limits Main Fuel Burner Motor 3 4 Ignition Alarm A S T S T 2 TYPICAL FIREYE UVM-1 Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N DATE: 3/06/06 3-77

IntelliCon LCH or LCS With FIREYE UVM-1D, 1F, 2A, 3 TFM-1D, 1F, 2A, 3 IntelliCon Original TAPE OFF To Flame Detector DATE: 7 1 Limits 8 4 Burner Motor Ignition A 6 Alarm Air Flow Switch S1 3 No 1 Oil Valve S2 2 TYPICAL FIREYE UVM, TFM Note: Not all terminals shown. LIMIT CONTROL (Not Used On TFM Models) 120VAC POWER H N 3-78 3/06/06

IntelliCon LCH With FIREYE UVM-2A and TFM-2A IntelliCon Original TAPE OFF To Flame Detector DATE: 7 1 Limits 8 4 Burner Motor Ignition A 6 Alarm Air Flow Switch S1 3 S2 No 1 Oil Valve/Pilot Gas Valve 2 TYPICAL FIREYE UVM, TFM Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N 3/06/06 3-79

IntelliCon LCH or LCS With FIREYE UVM-3 and TFM-3 IntelliCon Original TAPE OFF To Flame Detector DATE: 7 1 Limits 8 4 Burner Motor Ignition A 6 Alarm Air Flow Switch S1 3 S2 No 1 Oil Valve/Pilot Gas Valve 2 TYPICAL FIREYE UVM, TFM Note: Not all terminals shown. LIMIT CONTROL (Not Used On TFM Models) 120VAC POWER H N 3-80 3/06/06

Honeywell Flame Safeguard Controls General Instructions The IntelliCon Heating Economizers are connected in series in the burner control circuit AFTER the operating safety s and limit controls and BEFORE the burner Flame Safeguard Primary Control. ***ATTENTION MUST BE GIVEN WHEN A DRAFT INDUCER IS USED ON THE BOILER*** *** When a draft inducer is being used, the operating limit control, on closure, will activate a relay, contactor or starter to enable the draft inducer. An air proving switch will close indicating that the draft inducer is running and a negative air flow has been established through the boiler. Once the negative airflow has been established the Flame Safeguard is enabled and starts the burner sequence. Improperly connected into the operating limit circuit, the draft inducer will run drawing ambient (or cooler) air through the boiler while the IntelliCon Heating Economizer is in the ECONOMY mode. Each installation should be checked for the proper connection point of the IntelliCon Heating Economizer. The following wiring diagrams show the connection points of the IntelliCon Heating Economizer at the Honeywell Flame Safeguard ONLY. If a draft inducer is used as explained above, determine the connection point from the operating limit control BEFORE the Flame Safeguard Control. 3/06/06 3-81

7 IntelliCon CHS or CHW With Honeywell R4140G, L,M or R4150A, C, X IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS Limits And Burner Controller DATE: TYPICAL R4140 or 4150 Original INCOMING POWER CONNECTIONS 24 115/220 CALL BURNER 220 115 24 COMMON COMMON SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW NOTE: Add jumper as shown between terminals "115/220" and "COMMON" 120vac Hot L1 8 Burner Motor 120VAC POWER 120vac Neutral L2 Main Fuel Valve/s H N F G 6 4 Pilot/ Ignition Limit Circuit Alarm 9 3 Lockout Interlockouts Note: Not all terminals shown. 3-82 3/06/06

IntelliCon CHS or CHW With Honeywell R4795A,D IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SUMMER/WINTER SWITCH SENSOR CONNECTORS SUMMER = N.C. WINTER = N.O. 115/220 24 CALL BURNER 220 24 COMMON 115 COMMON S/W SW Limits And Burner Controller NOTE: Add jumper as shown between terminals "115/220" and "COMMON" Original 1 8 Burner Motor 5 2nd Stage Oil Valve 4 Ignition To Flame Detector Air Switch 7 F 3 1st Stage Oil Valve 6 Air Switch 120VAC POWER H N G TYPICAL R4795A,D Note: Not all terminals shown. 2 3/06/06 3-83

IntelliCon CHS or CHW With Honeywell R7795A, B, C, D IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW NOTE: Add jumper as shown between terminals "115/230" and "COMMON" DATE: 9 5 Alarm Burner Motor 8 Original 18 Pilot Valve Ignition 16 3 To Flame Detector F 6 Air Switch Main Fuel Valve G L2 TYPICAL R7795 Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N 24 115/220 CALL BURNER 220 115 24 COMMON COMMON 3-84 3/06/06

IntelliCon CHS or CHW With Honeywell RM7800/RM7840 E, G, L, M IntelliCon Wiring Compartment FUTURE USE BURNER CONTROL CIRCUIT CONNECTIONS INCOMING POWER CONNECTIONS SUMMER/WINTER SWITCH SUMMER = N.C. WINTER = N.O. SENSOR CONNECTORS S/W SW NOTE: Add jumper as shown between terminals "115/230" and "COMMON" 3 4 Alarm Burner Motor 5 Original 10 Ignition 6 7 Interlocks To Flame Detector F 9 G Main Fuel Valve L2 TYPICAL RM7800/RM7840 E, G, L, M Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N 24 115/220 CALL BURNER 220 115 24 COMMON COMMON 3/06/06 3-85

IntelliCon LCH with AO Smith DuraMax Models DB/DW 720-1810 FLOW SWITCH 120vac Neutral 120vac Hot TERMINAL STRIP 8 7 6 5 4 3 2 1 TAPE OFF IntelliCon LCH COMBINATION HIGH LIMIT MANUAL HIGH LIMIT AUTO RESET HIGH LIMIT MV MV/PV PV GND 24V (G) 24V SPARK C NO NC SYSTEM CONTROLLER OR TANK TEMP. CONTROLLER 3 2 1 SWITCH THERMAL BALANCER NOTE: NOT ALL CONTROLS AND WIRING SHOWN TRANSFORMER R C GREEN IGNITION MODULE Original 3-86 3/06/06

3/06/06 3-87 IntelliCon LCH Or LCS With Honeywell R890E, F, G IntelliCon TAPE OFF 6 5 T 4 T 3 F 1 G 2 TYPICAL R890 Note: Not all terminals shown. LIMIT CONTROL 120VAC POWER H N

7 IntelliCon LCH or LCS With Honeywell R4140G, L,M or R4150A, C, X IntelliCon TAPE OFF 120VAC POWER H N 120vac Hot L1 8 Burner Motor 120vac Neutral L2 Main Fuel Valve/s F 6 Pilot/ Ignition G 4 Limit Circuit 9 Alarm Lockout Interlockouts TYPICAL R4140 or 4150 3 Note: Not all terminals shown. Original Limits And Burner Controller 3-88 3/06/06

IntelliCon LCH OR LCS With Honeywell R4795A,D IntelliCon TAPE OFF To Flame Detector LIMIT CONTROL 1 5 2nd Stage Oil Valve Burner Motor 8 4 Ignition 7 3 Air Switch F 6 1st Stage Oil Valve G 2 Air Switch TYPICAL R4795 Note: Not all terminals shown. 120VAC POWER H N 3/06/06 3-89

3-90

IntelliCon LCH OR LCS With Honeywell RM7800/RM7840 E, G, L, M IntelliCon TAPE OFF To Flame Detector LIMIT CONTROL 3 4 Alarm Burner Motor 5 Original 10 Ignition 6 7 Interlocks F 9 G Main Fuel Valve L2 TYPICAL RM7800/RM7840 E, G, L, M Note: Not all terminals shown. 120VAC POWER H N 3/06/06 3-91

IntelliCon LCH OR LCS With Honeywell RM7895 IntelliCon TAPE OFF To Flame Detector LIMIT CONTROL/S 3 5 Alarm Burner Motor 4 Original 10 Ignition 6 7 Interlocks F 22 G 9 Main Fuel Valve L2 TYPICAL RM7895 Note: Not all terminals shown. 120VAC POWER H N 3-92 3/06/06

REFRIGERATION CAUTION: Read and follow these general instructions and the instructions that are packed with the IntelliCon Model RU. Failure to follow these instructions could result in damage to the system or cause a hazardous condition. General Instructions PUMP DOWN SYSTEMS: When installing the Model RU on pump down type refrigeration systems the IntelliCon RU should be connected so that the call for the liquid line solenoid valve is delayed from opening instead of delaying the compressor. This assures that the evaporator is not flooded with refrigerant. OIL PRESSURE SAFETY CONTROLS: CAUTION: Do not connect the IntelliCon RU after the oil pressure safety control! Some commercial refrigeration systems utilize compressor oil pressure safety controls. The compressor oil pressure safety control has a time delay to allow the compressor to build up proper oil pressure. This time delay is energized on a call for the compressor to run. If the IntelliCon RU is wired incorrectly in the control circuit, the oil pressure safety control could time-out resulting in a manual reset lockout condition. The wiring diagrams that follow show the correct installation of the IntelliCon RU in such a system. NOTE: The following diagrams are representative of typical refrigeration systems and do not show all controls that may be in your particular system. Actual system wiring may differ 5/31/2006 1

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IntelliCon Application Guidelines Applications: Packaged Air Conditioning Units Split Type Air Conditioning Units Self Contained, Air or Water Cooled Air Conditioning Units Heat Pumps, (water source or air to air) Residential Hot Water Heating Systems (Demand Type) Residential Heat Pumps Residential Central Air Conditioning Residential Forced Warm Air Furnaces (gas or oil fired) Commercial Forced Warm Air Units (Stand-Alone or Packaged Rooftop HVAC, gas or oil fired) Commercial Refrigeration (>1.0 HP) Commercial Steam Heating Boilers (with or without a Domestic Hot Water Coil) Commercial Hot Water Heating Boilers (with or without a Domestic Hot Water Coil) Commercial Hot Water Heaters (gas or oil only) Indirectly Heated Absorption Chillers Screw Type Compressors (Used in Demand Applications) Non-Applications: Centrifugal Compressors Screw Compressors (Proportionally Controlled) Commercial Refrigeration (< 1HP) Refrigeration Cascade Systems Refrigeration Rack Systems (Pending release of PDL product) Ice Machines Direct Fired Absorption Chillers (Pending release of DFC product) Window or Wall Type Air Conditioners (Pending release of ACW product) Ductless Mini Split Air Conditioning (Pending release of ACW product) Heated Make up Air Units Chillers or Boilers used for Process Control Electric Hot Water Heaters Milli-Volt or Self Generating PowerPile Systems York Millinium Chillers Proportionally Controlled Chillers Carrier FloTronic Chillers 5/31/2006 1