intelliGen™ refrigeration control | The Hub
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Instruction Manual for HEATCRAFT models including: H-IM-iFM intelliGen Field Mount iFM Kit, H-IM-iFM, intelliGen Field Mount iFM Kit, Field Mount iFM Kit, Mount iFM Kit, iFM Kit
intelliGen™ refrigeration control | The Hub
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DocumentDocumentintelliGen Field Mount (iFM) Kit H-IM-iFM November 2024 Part No. 25011801 Installation and Operation Manual Scan QR code to view the manual online Table of Contents intelliGen Components inteinlltieGlelinGeBnoaFriedld(iRMCo)uLnaty(oiFuMt .)..K..i.t.s.........................22 inteClolimGepnonUesnetrsInteeerdfaecdef(oiRr CInUsIt)aLllaytioount.................23 IntePlrleiGpeanraRtieomn ofoter AIncscteasllsatCioanrd..s...(.i.W...C..,..i.IC...)............ 33 InsCtaomllaptoionnen&tsWInircilnugded in Kit..........................4-7 InsCtaolmlatpioonneTniptss N...o..t..I.n.c..l.u..d..e..d...i.n..K...it...............................................84 EvaEpleocratrtoonricUnEixt p.a..n..s.i.o..n...V..a.l.v..e...E..X..V..........................................8..-..94 ConFideeldnsWinirgeUCnoitnbnyecOtitohnesrs...................................................................1. 04 RSpefeUrcnigiiatelrCaConootnleLdriennPesroBindrgauzcUitnnFgitabm..y.i.l.Hi.e.e.s.a..St.c.u.r.pa.p.f.to...r..t....e..d.................................1....155 LeaMkaTinesCtionngtr.o..l..B..o..a..r.d...(.i.R..C..)..L..a..y.o..u..t..........................................1. 25 RefUrsigeerrIanntet rCfahcaerg(iinRgC.U..I.)..L..a..y.o..u..t....................................................1..35 PowOpertioSnuaplpRlye.m...o..t.e..A...c.c..e..s..s..C...a.r..d..s..............................................1..35 WirTiynpgic..a..l..W...i.r.i.n..g..D...i.a..g.r..a..m...s........................................................1..4. -51-57 WirRinegmToetermMinoaulnst..i.n.t..e.l.l.i.G..e..n...C..o..n..t.r.o..l.l.e..r............1..6..-.1..78 WirCinogmDpoiangernatms sIn.s..t.a..l.l.a.t..io..n...i.n...U..n..i.t..C..o..o..l.e..r.......1..89--2210 InsRtaeltlarotifoitnoCf haencEkxliisstti.n..g...U..n..i.t..C..o..o..l.e..r................... 2221 StaCrht-eucpk-&OuOtpInesratatliloantion................................... 23 CheScyks-teOmutSIntasrttalUlaptsio.n.......................................................................2..4..-.2252 InitiiFaMl PKoiwt AerccOenss..o.r..ie..s.................................................................................2262 System Start-up ............................................... 23 Cooling Start-up Operation ............................... 23 Home Menus & PIN............................................. 24 Navigation, System & Local .............................. 24 Menus and Settings .....................................25-31 Cooling Sequence of Operation .......................... 32 Defrost Sequence of Operation............................ 33 intelliGen Field Mount (iFM) Kits intelliGen Field Mount (iFM) Kits for Unit Coolers The intelliGenTM Field Mount Kit is designed to install in the field for new unit coolers without factory mounted controls or retrofit of existing unit coolers with mechanical control to upgrade to electronic control. The intelliGen control can be remote mounted up to 40 feet from the unit cooler at a convenient location for easy access. The intelliGen control is pre-assembled in a IP65 rated housing for both indoor and outdoor applications. It supports Heatcraft's major unit cooler product lines such as the Low Profile, Center Mount and Low Velocity Center Mount, Medium Profile, High Profile Large Unit Coolers and others. It is universal fit for field mount and retrofit for all air and electric defrost unit coolers for refrigeration. Light Bar Alerts Color coded LED immediately shows the status of your system. Full-Text Display Guided text instruction for setup and service. Quick Menu Buttons Establish preferred settings and quickly make changes. Turn & Press Knob Quickly navigate system configuration and servicing. Ready-to-Mount Plastic Housing Waterproof seal for indoor & outdoor applications. All electronics pre-installed. Components Needed for Installation The iFM kit comes with the intelliGen controller, 3 temperature sensors, 1 pressure transducer with cable, 1 terminal board and mounting accessories. The temperature sensors and pressure transducer cable are 25 feet in length. Other wire lengths are available as optional kit in separate part numbers. See Components Included section for details. There are individual system dependent components are not included but required for each installation. These components include the 24VAC control power transformer, the electronic expansion valve (EXV), the power wires for control power, fan motors, defrost heaters and solenoid 2 valve. Not all applications require defrost heaters and solenoid valve, check the system requirement for wiring needs. See Components NOT Included section for details and availability options. Field wire runs between the intelliGen controller and the unit cooler should be in conduits and have to meet local building and electric code requirements. Conduit fittings are needed for the conduit runs. Please conduct a site survey and review your local codes for detailed requirements prior to installation. Low voltage and communication wires need to run in separate conduit from the high voltage wires to minimize interference. intelliGen Field Mount (iFM) Kits Preparation for Installation Toooollss NNeeeeddeedd TToooollss DesUcrsieption TToolss SlotteSdSlloSoctttreeeddwSdcrive SSccrreewwddrriivveerr PPhhiilllliippss SSccrreewwddrivveerr PPrreecciissiioonn SSllootttteedd SSccrreewddrriivveerr 5//1166"NNuutt DDrriveerr PowPeowr DerriDllri&ll &Drill DrBilil tBsits Power Drill & Drill Hacksaw Bits DescUrsipetion WrWernecnhc,h7, /71/166a"nd and5/58/8" AAddjujussttaabblle WWrreenncchh WWirireeSSttrriippppeerr/ / CCrriimpeerr 5/32M" uHletxim(Aellteenr) Key W(FiiMsrMehaaPTrraukpleleerr) BraMzianrgkTeorols Toolss ToolsNMeeigdhetdBTeoNoelseded DesUcrsieption TToooollss SlotStWecrSdireleLoSwacMtbdtreaeerrlidwkveeSdrcrrive Phillips SMcruelwtimdreitveer r Precision Slotted Screwdrive 5/16 Nut Driver Power Drill & Drill Bits DesUcrsieption Wrench, 7/16 and Electri5c/a8l Tape AdjustMabalrekeWr rench Wire Stripper / Crimper Multimeter Marker 3 intelliGen Field Mount (iFM) Kits iFM Kit Part Number: 59755002 Components Included in the Kit intelliGen Controller Temperature Sensors Pressure Transducer Harness Temperature Sensor Brackets Wire Sheathing Terminal Board Pressure Transducer & Accessories Quick Start Guide & Manual 4 intelliGen Field Mount (iFM) Kits Components Included in the Kit · intelliGen Controller - Quantity of 1 Main control board and user interface board are pre-assembled in a IP65 rated housing. Knockouts (top & bottom) Knockouts · Temperature Sensors - Quantity of 3 For room temperature, suction temperature and coil temperature (25 feet length) · Pressure Transducer Harness - Quantity of 1 For suction pressure transducer connection (25 feet length) · Terminal Board - Quantity of 1 For power, fan motors and defrost heater wire connections 5 intelliGen Field Mount (iFM) Kits Temperature Sensor Brackets & Accessories Bag · Room Temperature Sensor Bracket - Quantity of 1 For mounting the room temperature sensor at the return air side of the unit cooler. · Suction Temperature Sensor Tube - Quantity of 1 For mounting the suction temperature sensor to the suction refrigeration line. · Coil Temperature Sensor Bracket - Quantity of 1 For mounting the coil temperature sensor to the coil. · Mounting Screws - Quantity of 4 Two screws for the coil temperature sensor mounting bracket. Two screws for the terminal board. · Cable Ties - Quantity of 2 Cable ties for securing the room temperature sensor to the mounting bracket. 6 intelliGen Field Mount (iFM) Kits Pressure Transducer & Accessories Bag · 300 PSI Pressure Transducer - Quantity of 1 Mount on the main suction line port to measure suction pressure. · Cork Tape Roll - Quantity of 1 Insulation tape for suction temperature sensor tube to prevent condensation · Cable Ties - Quantity of 2 Cable ties for securing suction temperature sensor inside the metal tube and the suction line · Wire Sheathing - Quantity of 4 Wrap wires inside the iFM kit housing for additional protection · Caution Label - Quantity of 1 Caution label for suction temperature sensor installation · Labels for User Interface Panel - Quantity of 1 Information labels to apply on user interface swinging panel Instruction Manuals Bag · iFM Kit Quick Start Guide · intelliGen Installation and Operation Manual 7 intelliGen Field Mount (iFM) Kits intelliGen Field Mount (iFM) Kits Components NOT Included in the kit but are needed for installation These are system dependent components based on application. Field installer to provide these components separately based on the specific system requirement. · 24VAC Control Power Transformer quantity of 1 A 24VAC step down transformer from system voltages (120VAC, 208-230VAC, 460VAC or 575VAC) is needed to power the intelliGen control. Note: For small unit coolers like Heatcraft's Low Profile Unit Coolers with 460VAC or 575VAC system voltages, external contactors are required to power the motors and heaters due to limited cabinet space to mount the components. Heatcraft 24V AC Transformers PART # Description 22529601 120/24VAC, 40VA 22529602 240/24VAC, 40VA 22529603 460/24VAC, 40VA 22529701 575/24VAC, 40VA · Electronic Expansion Valve EXV Quantity of 1 (If use EXV is preferred) These EXVs are available from Heatcraft. Field installer to select and provide one of these valves to match the system capacity requirement. A valve cable with the length matches the conduit run is also required. PART NUMBER 29326101 29326201 29326401 29326501 29326601 R-22 Evaporator Temperature (°F) 100 psi Pressure Drop +20 -20 TONS BTUH TONS BTUH 0.44 5220 0.41 4920 4.25 51000 3.99 47900 7.52 90260 7.54 90480 15.14 181680 14.25 171000 22.18 266160 20.87 250440 R-404A/R-507 Evaporator Temperature (°F) 100 psi Pressure Drop +20 -20 TONS BTUH TONS BTUH 0.73 8706 0.64 7692 3.11 37309 2.75 32966 4.66 55964 4.12 49449 10.89 130692 9.62 115480 16.08 192985 14.21 170521 PART NUMBER 29326101 29326201 29326401 29326501 29326601 R-407A Evaporator Temperature (°F) 100 psi Pressure Drop +20 -20 TONS BTUH TONS BTUH 0.99 11831 0.90 10808 4.23 50704 3.86 46320 6.34 76056 5.79 69481 14.80 177616 13.52 162259 21.86 262273 19.97 239598 R-407C Evaporator Temperature (°F) 100 psi Pressure Drop +20 -20 TONS BTUH TONS BTUH 1.07 12898 0.99 11863 4.61 55279 4.24 50839 6.91 82919 6.35 76258 16.14 193641 14.84 178088 23.83 285938 21.91 262970 8 intelliGen Field Mount (iFM) Kits intelliGen Field Mount (iFM) Kits PART NUMBER 29326101 29326201 29326401 29326501 29326601 R-407F Evaporator Temperature (°F) 100 psi Pressure Drop +20 -20 TONS BTUH TONS BTUH 1.09 13067 1.01 12094 4.67 56001 4.32 51831 7.00 84001 6.48 77746 16.35 196168 15.13 181562 24.14 289669 22.34 268100 R-448A Evaporator Temperature (°F) 100 psi Pressure Drop +20 -20 TONS BTUH TONS BTUH 1.01 12128 0.92 11098 4.33 51977 3.96 47561 6.50 77966 5.95 71341 15.17 182075 13.88 166604 22.40 268859 20.50 246014 PART NUMBER 29326101 29326201 29326401 29326501 29326601 R-449A Evaporator Temperature (°F) 100 psi Pressure Drop +20 -20 TONS BTUH TONS BTUH 1.01 12125 0.92 11083 4.33 51965 3.96 47499 6.50 77947 5.94 71249 15.17 182030 13.87 166389 22.40 268793 20.47 245696 Cables for Carel EXV PART NUMBER DESCRIPTION 22592201 10ft cable for Carel EXV 22592103 25ft cable for Carel EXV 22592102 40ft cable for Carel EXV Sporlan SER and SERI Series of Electronic Expansion Valve Support The Sporlan SER and SERI Series of electronic expansion valves are supported. This valve option is selectable in the intelliGen Quick Start initial setup process. See Sporlan's website and document for SER and SERI Series valve sizes and selection https://solutions.parker.com/sporlanvirtualengineer 9 intelliGen Field Mount (iFM) Kits Field Wire Connections Power wires between system components and the intelliGen controller The field wire connections are to be provided by the field installer. A 25 feet long power harness with connectors and terminals preassembled is available from Heatcraft for ease of installation. The part number is 22699902. It includes the power wires listed below. · 24VAC power wires for intelliGen control two 18 AWG wire with ¼" quick connect terminal on one end and ¼" piggyback quick connect terminal on the other end · Fan motor wires two 18 AWG wires with ¼" female quick connect terminals on both ends · Defrost heater wires two 14 AWG wires with fully insulated ¼" female quick connect terminals on both ends, and two 18 AWG wires with fully insulated ¼" female quick connect terminals on both ends. (Wires need depend on application.) · Solenoid valve control wires two 18 AWG wires with ¼" female quick connect terminals on one end and bare wires on the other end. (Wires need depend on application.) PART # 22699903 22699902 22699901 Heatcraft Power Harnesses Description 15ft harness for power, fan, defrost heater 25ft harness for power, fan, defrost heater 40ft harness for power, fan, defrost heater Note: For systems with defrost heater load higher than 30 Amp, external contactors are required to power the defrost heaters. The defrost heaters relay on the intelliGen controller use as pilot relay for the external contactors. Conduit runs for field wires Field wires between the intelliGen controller and the unit cooler should be in conduits and meet local building and electric code requirements. Conduit fittings are also needed based on installation application. A site survey and installation planning is recommended to determine conduit lengths and the type of conduit fittings and quantity needed. It is required to run power wires and low voltage (sensors and communication) wires in separate conduits. Wire Protection High voltage and low voltages wires inside the iFM kit requires additional insulation protection. Wire sheathing should cover all wiring within the iFM enclosure. Sets of wire sheathing are provided with the iFM kit. High voltage wires may share a sheath, and low voltage wires may share a sheath, but each group should be separately sheathed to maintain separation. 10 intelliGen Field Mount (iFM) Kits Unit Cooler Product Families Supported The iFM Kit is designed to universal fit for Heatcraft's Unit Coolers and other manufacturer's Unit Coolers also. Low Profile Unit Cooler Center Mount Unit Cooler Low Velocity Center Mount Unit Cooler Medium Profile Unit Cooler High Profile Large Unit Cooler 11 intelliGen Field Mount (iFM) Kits intelliGen Main Control Board (iRC) Layout Defrost Heater Relay Evap Fans Relay Evap 2 Speed Fans LLSV Relay Alarm Contacts EXV Grounded Mounting Screw EXV Capacitor Clock Battery USB Data Port Central Processing Unit Box Temp Suction Temp Coil Temp Suction Pressure Grounded Mounting Screw Aux Temp 24V Power Supply iRC-UI Connection Chasis Ground Spare I/O Evap Communication Connection Product Load Switch Grounded Mounting Screw Condensing Unit Connection Door Switch 12 intelliGen Field Mount (iFM) Kits intelliGen User Interface (iRCUI) Layout OLED Display Return Button Home Button Status Light Bar Favorites Button Control Button intelliGen Optional Remote Access Cards MULTI-SYSTEM CONTROL CARD - MSC WEBSERVER CARD - iWC Wi-Fi Direct Antenna* INTEGRATION CARD - iIC Wiring Terminal Ethernet Connector Scan QR code to view the manual or visit www.intelliGencontrols.com/resources Screw Mount Holes NOTE: Refer to iWC & MSC Installation & Operation Manual (H-IM-iWC/MSC for installation and maintenance instructions. * MSC card comes with Wi-Fi Direct antenna and the iWC webserver card does not come with Wi-Fi Direct antenna. LEGEND Long Name Evap/Evaporator Set-Point Auxiliary Temperature/Temp Calibration Electronic Expansion Valve Condensing Unit Compressor Connection Lead-Lag Abbrev. Name EV SP AUX TEMP CALIB EXV CU COMP CXN LL 13 iFM Kit Installation Section Typical Wiring Diagram For Applications With Contactors Typical Wiring Diagram For Applications Without Contactors 14 TDR to be bypassed or removed when installing iFM Kit Installation Section Typical Generic Condensing Unit Wiring Diagram for intelliGen Stand-alone Evaporator Controller 15 iFM Kit Installation Section Remote Mount intelliGen Controller 1. Identify Remote Mount Location The iFM kit designed to be remote mounted up to 40 feet away from the unit cooler. The kit comes with 25 feet long wire sensors. A 40 feet long wire sensors kit is available separately. It can be mounted outside of a walk-in cooler, near the entrance door. a) Identify a flat surface to mount the iFM kit b) Prepare the mounting location and mark screw holes Pro Tip: Use the iFM kit housing or the housing outline on the Quick Start Guide and mark the four screw holes 2. Route Conduits and Wires to Unit Cooler a) Determine length and conduit routing base on application need b) Determine the knockout on the iFM kit housing to use for conduit and wires routing. (1-1/2" and 7/8" knockouts are available at the top, bottom and the top left side of the housing.) c) Determine the conduit fittings for connecting the conduit to the iFM housing d) Run wires through the conduits e) Connect fittings to the conduits Knockouts (top & bottom) Knockouts iFM Kit Assembly Dimensions (inch) Pro Tip: Use knockouts on the left side or the top side for power wires and use the knockouts on the bottom for sensors and communication wires. 16 IntelliGen Board Layout Remote Mount intelliGen Controller (Cont.) 3. Mount the iFM Kit a) Mount the iFM kit housing to the marked screw hole locations with #10, 1-1/4" long screws b) Pull the wires through the knockouts on the iFM housing c) Tighten the conduit fittings to the conduit and to the iFM housing Defrost Heater Relay Evap Fans Relay Evap 2 Speed Fans 4. Connect the wires to the intelliGen control board a) Connect wires to the iRC main control board per the connections layout below. LLSV Alarm Relay Contacts EXV Grounded Mounting Screw EXV Capacitor Clock Battery USB Data Port Central Processing Unit Box Temp Suction Temp Coil Temp 24V Power Supply iRC-UI Connection Suction Pressure Chasis Ground Grounded Mounting Screw Grounded Mounting Screw Aux Temp Spare I/O Evap Communication Connection Product Load Switch Condensing Unit Connection Door Switch 17 New Unit Cooler Installation Components Installation in Unit Cooler 5. Power Transformer a) Select a 24VAC transformer with the primary voltage matches the system voltage b) Mount the transformer to the electrical end of the unit cooler, see picture shown as example Terminal Board 24VAC Transformer STEP 5 & 6 6. Terminal Board a) Mount the terminal board to the electrical end with the screws provided Pro Tip: Mount the new terminal board at the same location of the existing terminal board for incoming power b) Connect the wires (transformer power, heater wires, motor fan wires, solenoid valve wires) as needed per the system requirement to the terminal board. See wiring diagrams in the System Wiring Diagrams Section on Pages 14 and 15. 18 New Unit Cooler Installation Components Installation in Unit Cooler (Cont.) 7. Temperature Sensors a) Room Temperature Sensor i. Drill two ¼" holes, 1-1/4" apart, on the return air area of the unit cooler (typically at the back of the unit) ii. Insert the Room Temperature Sensor Bracket into the two drilled holes as shown in the picture iii. Use cable ties to secure the Room Temperature Sensor to the bracket as shown in the picture b) Suction Temperature Sensor i. Braze the metal Suction Temperature Sensor Tube onto the suction line ii. Insert the temperature sensor into the metal tube iii. Wrap the temperature sensor and the metal tube with cork tape iv. Secure the temperature sensor with the cable ties provided as shown in the picture c) Coil Temperature Sensor i. Attached the Coil Temperature Sensor onto the Coil Temperature Sensor Bracket provided ii. Screw tight the sensor bracket onto the coil end plate with the self-drilling screws provided. See picture as example Suction Temperature Sensor Room Temperature Sensor STEP 7a Coil Temperature Sensor STEP 7b STEP 7c 19 New Unit Cooler Installation Components Installation in Unit Cooler (Cont.) 8. Pressure Transducer a) Locate the Schrader valve on the suction line. (Depends on system, a new Schrader valve may have to be installed or brazed onto the suction line.) b) Screw the pressure transducer onto the Schrader valve. Pro Tip: Use correct tools to prevent damage to the Schrader valve and the copper pipe. Use 7/16" wrench to hold steady of the Schrader valve at the bottom, then tighten the pressure transducer at the top with a 5/8" wrench c) Plug in the pressure transducer harness and make sure the harness clip securely latches over the pressure transducer, see picture as example Pressure Tranducer STEP 8 20 New Unit Cooler Installation Components Installation in Unit Cooler 9. Electronic Expansion Valve (EXV) a) Select an EXV with capacity size that matches the unit cooler capacity b) Remove the EXV body from its motor/head c) Braze the EXV in place to the distributor connection and the liquid line stub to the EXV using proper brazing techniques d) Connect the wiring harness and the motor/head i. Push the external motor stator assembly onto the top of the valve ii. Tighten the mounting thumb nut to the hold the motor in place on the top of the valve iii. Smear a small amount of dielectric grease between the pins on the top of the motor. If dielectric grease is not available, automotive ignition grease can be used. (DO NOT use silicone.) iv. Connect the wiring harness to the top of the motor/ head assembly. v. Now the valve had been successfully installed and ready for operation. Pro Tip: This is to eliminate moisture presence between the pins and the control harness. Electronic Expansion Valve (EXV) Pro Tip: Make sure the motor/head of the EXV is not pointing down. It should be pointed upward or horizontal. STEP 9 Pro Tip: The proper orientation of the harness plug is for the cable to run to the right as you are facing the Carel brand name on the motor/head. The plug has one wide slot that is to align with a wide spade connector on the motor/head. Do not exert torque or deforming stress on the valve or the connection pipes. Do not hit the valve with hammers or other objects. Do not use pliers or other tools that may deform the external structure or damage the internal parts. Never aim the flame at the valve. Never place the valve near magnetic fields. Never install or use the valve in the event of: · deformation or damage to the external structure; · heavy impact, due for example to dropping; · damage to the electrical parts (stator, contact carrier, connector,...) 21 Existing Unit Cooler Installation Retrofit of An Existing Unit Cooler Pump Down the Unit Cooler 1. Put the existing unit cooler into service mode and pump down the unit. 1.1. Wait for the system to pump down and shut off. It could take up to 5 minutes. 2. Disconnect power to the unit cooler 3. Evacuate the system with proper refrigeration evacuation procedure (check I&O for unit coolers for additional steps) Remote Mount intelliGen Controller 1. See section Pages 16 and 17 for instructions of installing the remote mount intelliGen controller Components Installation in Unit Cooler 2. Disconnect wires and remove the existing terminal board in the electrical end of the unit cooler and replace with the new terminal board provided and a 24VAC trans former. 3. Remove the existing mechanical expansion valve (TXV) in the distributor end of the unit cooler and replace with a new electronic expansion valve (EXV) a.) Cut and remove the TXV from the copper pipes. 4. See Pages 18 to 21 for instructions of installing new transformer, terminal board, temperature sensors, pressure transducer and EXV. 5. Wiring to solenoid valve (if needed by application) f) Disconnect the existing wires terminated on the solenoid valve g) Connect the two wires from the iFM controller to the solenoid valve Terminal Board at Electrical End STEP 2 & 4 Thermal Expansion Valve (TXV) Solenoid Valve STEP 3 & 4 22 Equipment StartUp Check-Out Installation After the installation has been completed, the following points should be covered before the system is placed in operation: (a) Check all electrical and refrigerant connections. Be sure they are all correct and tight. (b) Check voltage taps on transformer at the evaporators for proper supply voltage connection if a multitap transformer is used. (c) Check high and low pressure controls, pressure regulating valves, oil pressure safety controls, and all other safety controls and adjust them, if necessary. (d) On freezers only, check the low pressure switch setting. It must be set to 0 PSIG cut out, 10 PSIG cut in, to allow start and operation, especially in cold ambients. Applies to special intelliGen condensing units only. (e) Suction and liquid lines should always be insulated. (f) Wiring diagrams, instruction bulletins, etc. attached to the condensing units should be read and filed for future reference. (g) All fan motors on air cooled condensers, evaporators, etc. should be checked for proper rotation. Fan motor mounts should be carefully checked for tightness and proper alignment. (h) Observe system pressures during charging and initial operation. Do not add oil while the system is short of refrigerant unless oil level is dangerously low. (i) Continue charging until system has sufficient refrigerant for proper operation. Do not overcharge. Remember that bubbles in a sight glass may be caused by a restriction as well as a shortage of refrigerant. CAUTION: Extreme care must be taken in starting compressors for the first time after system charging. At this time, all of the oil and most of the refrigerant might be in the compressor creating a condition which could cause compressor damage due to slugging. Activating the crankcase heater for 24 hours prior to start-up is recommended. If no crankcase heater is present, then directing a 500 watt heat lamp or other safe heat source on the lower shell of the compressor for approximately thirty minutes will be beneficial in eliminating this condition which might never reoccur. Initial Power On When power supply is connected to the iRC for the first time, a series of inputs is required to identify specific system parameters. Since there are no factory set-point defaults pre-setup, the Quick Set-up procedure is triggered to capture essential information about the system when the system is first energized. This also occurs when a new iRC board is installed on a single evaporator system. Inputs for the Quick Set-up are made using the iRC user interface (UI) control. The Control Knob on the iRC UI is used to navigate through the required steps and to identify selections. Turning the knob will navigate through possible selections for that particular parameter. Pressing the Control Knob makes selections (similar to an Enter key on a PC). 23 Equipment StartUp System Start-up When the system is initiated for the first time, the compressor and the electric defrost evaporator fans will be in a hold-off cycle and will not start unless the hold-off cycle is complete. The electric expansion valve (EXV) then opens to 50% and will begin its superheat control sequence. The compressor starts and will be in a "hold-on" cycle. (This is to minimize short-cycling of the system). At initial start-up, the system may cycle off after a few minutes and display a low superheat error, then restart itself. This cycle may be repeated a few times. Do not shut the system off. Let the system run, as it may take a few cycles for the electric expansion valve to attain the correct setting for the set superheat. Do not leave the unit unattended until the system has reached normal operating conditions with the box pulled down to design conditions and the oil charge has been properly adjusted to maintain the oil level at the center of the sight glass. When the room thermostat setting is satisfied (which may take a considerable amount of time on "hot-box" pulldown), and if the compressor has run for a minimum time for the "hold-on" cycle, the EXV will close (shutting off the refrigerant flow to the evaporator), and the system will pumpdown and shut off. The evaporator fans will continue to run. Call for Cooling Start-up Operation When the box temperature sensor detects a rise of approximately half the box temperature differential, and the system has been off a minimum of the hold-off cycle time, the EXV will open to its last position, and the compressor will start. The EXV is then adjusted as necessary to obtain and maintain the superheat setting. During this time, the compressor will run for a minimum of the "hold-on" cycle time. 24 intelliGen System Start Up intelliGen System Start Up 1. Follow the intelliGen "QUICK START GUIDE" to start up the system 2. For remote access installation of the webserver card (iWC) the Multi-system Control Card (MSC) or the integration card (iIC) 2.1. See the remote access section of the intelliGen Installation and Operation Manual 3. For diagnostics and troubleshooting of the intelliGen system, see Diagnostics & Troubleshooting Section of the intelliGen I&O manual 4. To find all intelliGen resources, including installation & operation manuals, technical bulletins, brochures, main tenance, troubleshooting information and more, simply scan the QR code or use the link below. www.intelliGencontrols.com/resources 25 iFM Kit Accessories intelliGenTM Accessories and Service Parts PART # Description Field Mount Kit 59755002 intelliGen Field Mount (iFM) Kit with 25ft sensor lead wires Power Harness 22699903 15ft harness for power, fan, defrost heater, solenoid valve 22699902 25ft harness for power, fan, defrost heater, solenoid valve 22699901 40ft harness for power, fan, defrost heater, solenoid valve Temperature Sensors 89904903 Temperature Sensor Kit - White Leads, 3ft 59755302 15ft sensor kit (3 temperature sensors, 1 pressure transducer harness) 59755301 40ft sensor kit (3 temperature sensors, 1 pressure transducer harness) Pressure Transducer & Harnesses 28911202 Pressure Transducer 0 - 300 PSIA 22515107 Pressure Transducer Harness, 15ft 22515105 Pressure Transducer Harness, 40ft Transformers 22529601 Transformer 120/24 volt - 40 VA 22529602 Transformer 240/24 volt - 40 VA 22529603 Transformer 460/24 - 40 VA 22529701 Transformer 575/24 - 40 VA Electronic Expansion Valve (EXV) & Cables 29326101 Carel EXV E2V11FWAE0 - 3/8" x 3/8" Conn 29326201 Carel EXV E2V24FWAE0 - 3/8" x 3/8" Conn 29326401 Carel EXV E2V24FSME0 5/8" X 5/8" Conn 29326501 Carel EXV E3V45ASTE0 7/8" X 1 3/8" Conn 29326601 Carel EXV E3V55ASTE0 7/8" X 1 3/8" Conn 22592201 Cable for Carel EXV, 10ft 22592103 Cable for Carel EXV, 25ft 22592102 Cable for Carel EXV, 40ft 26 iFM Kit Accessories intelliGenTM Accessories and Service Parts PART # Control Boards 28918001S 28918201S 28918301S 28918302S 28918401S UI to iRC Ribbon Cables 22602101 22602102 22602104 22602103 Door Switch 22543102 EV-COM Cable 22596801 Description iRC Main Control Board Replacement Kit iRCUI User Interface Replacement Kit iWC Webserver Card Replacement Kit Multi-system Control with Lead-lag (MSC) Card Field Mount Kit iIC Integration Card Replacement Kit For Center Mount/Low Velocity Center Mount Unit Cooler, 8" Replacement Kit For Low Profile Unit Cooler, 14" Replacement Kit For Medium Profile and Large Unit Cooler, 24" Replacement Kit For Large Unit Cooler 35" Replacement Kit Door Switch Kit (includes door switch and 2 ft cable) EV-COM Cable 28" for Large Unit Cooler DUAL iRC Board Replacement Kit 27 Heatcraft Refrigeration Products, LLC 2175 West Park Place Blvd., Stone Mountain, GA 30087 www.heatcraftrpd.com Customer Service and Technical Support Normal Business Hours 8:00 AM 8:00 PM EDT (800) 321-1881 After Hours (after 5:00 PM EDT, weekends and holidays) (877) 482-7238 Since product improvement is a continuing effort, we reserve the right to make changes in specifications without notice. ©2024 Heatcraft Refrigeration Products LLC The name behind the brands you trust.TM CLIMATE CONTROL Commercial Refrigeration Parts