I.C.E. HTDM Food Process Unit User Manual

Industrial 51 Aikins Street

EXTINGUISH ANY OPEN

FOR YOUR SAFETY THE USE

MAINTAINACE CAN CAUSE PROPERTY DAMAGE OR DEATH. PLEASE READ THIS

ON, OPERATION AND MAINTAINANCE MANUAL THOUROUGHLY BEFORE

Commercial Winnipeg, MB
Equipment Canada, R2W 4E3
Manufacturing LTD.

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.

FOR YOU SAFTEY IF YOU
SMELL GAS FOLLOW THESE
INSTRUCTIONS,

1) OPEN WINDOWS

2) DO NOT TOUCH
ELECTRICAL SWITCHES

3)
FLAMES

4) CALL THE GAS
SUPPLIER IMMEDIATLY

Model:______________________ Serial Number:___________________

Job:________________________ Date of Installation:____________

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR

OF GASOLINE OR OTHER
FLAMMABLE VAPORS AND
LIQUIDS IN OPEN
CONTAINERS IN THE
VICINITY OF THIS
APPLIANCE IS HAZARDOUS

WARNING

INSTALLATI

INSTALLING OR SERVICING THIS EQUIPMENT

INSTALLERS RESPONSIBILITY

Installer please note: This equipment has been test fired and inspected. It has

been shipped free from defects from our factory. However, during shipment and

installation, problems such as loose wires, leaks or loose fasteners may occur.

It is the installer’s responsibility to inspect and correct any problems that

may be found.

INSTALLER/SERVICE CONTRACTOR

NAME:____________________________
ADDRESS:_________________________
TELEPHONE:_______________________
CONTACT:_________________________

2

Table of Contents

Receiving and Warehousing 3
General Handling instructions 3
General Installation Notes 3
Clearance to Combustables 4
Connecting the Flue 5
Electrical Connections 6
Gas Piping 6

Gas Vent 7

Duct Furnaces 7
Cooling 8
High Altitude 8
Indoor Units 8
General Operating Instructions 8
Start Up Procedures 8
Precautions 8
Gas Units 9
Start Up 9
Shut Down 10
Emergency Shut Down 10
Service Shut Down 10
Recommended Quarterly Maintenance 10
Recommended Yearly Maintenance 11
ICECON II Operators Manual 12
ICECON II Controller 13
Normal Start Up Sequence 14
Heat Modes 14
External Modulation Control 15
How the ICECON II Controller Responds to External Control 15
Switching From mA to VDC control 16
Available Options (Software Control) 17
Error Signals 19
Trouble Shooting 21
Tachometer Test Procedure 23
Discharge Sensor/RSP Test 24
Wiring 25
Appendix A 26
Programming the ICECON II Controller 27
Setting Up the Software 27
The Main Interface 28
The System Tune Interface 29
I/O View 30
Set Points 31
Altering Combustion Set Points 32
Calibrating the Tachometer 32
Adjusting combustion Points 33
Saving an ICECON II Program 34
Uploading an ICECON File 34
Appendix 36
ICECON I to ICECON II Upgrade 37

3

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.
b) Equipment must be lifted simultaneously by all “eye” bolts or

channel slots provided on each section at the same time to
distribute the loading properly. Damage or injury may result
if all provisions for lifting are not utilized at time of
lift. When multiple lifting eyes are furnished they are to
share the weight of the lift evenly via spreader bar(s).

c) Lifting eyes and channel slots are designed to be lifted

vertically. The MAXIMUM angle from a vertical lift, which is
permitted, is 30 degrees. Single sections only are to be
lifted at one time and stacked from the lowest section
upward. Sections are designed to be self-supporting in
compression only. Do not attempt to hang multiple sections
from any structure. The total perimeter base and all frame
structure must be supported, and levelled, on high-density
concrete or sufficient I-beam steel.

d) For some models the heating and blower sections may be

shipped separately. Assemble the sections by aligning the
base frames and/or the pre-drilled flanges and secure the
assembly with the fasteners provided. Use gasketing material
to prevent infiltration at the joints.

WARNING

FAILURE TO COMPLY WITH THE GENERAL REQUIREMENTS MAY RESULT IN

EXTENSIVE PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.

GENERAL INSTALLATION NOTES

a) In Canada the installation must conform with local building

codes or, in the absence of local building codes, with the
current CAN/CGA -BI49.1 or B149.2 “Installation Codes for
Gas Burning Appliances and Equipment”. Indoor duct furnaces

4

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. NFPA standards are available from the
National Fire Protection Association, Batterymarch Par,
Quincy, Massachusetts 02269. Heaters referred to in this
manual are designed for use in airplane hangers when
installed in accordance with ANSI/NFPA No.409 and in public
garages when installed in accordance with the NFPA No. 88a

and NFPA No.88b.
c) No alterations are to be made on this equipment.
d) For suspended appliances which are installed in air craft

hangers, parking structures, and repair garages must be

installed in accordance with the standard on air craft

hangers, ANSl/NFPA 409, the standard for parking structures.

ANSI/NFPA 88a, the standard for repair garages, ANSI/NFPA

88b, and with the CAN I-B149 codes,

CLEARANCE TO COMBUSTIBLE MATERIALS in inches (mm)

MODEL TOP FRONT BACK FLOOR SIDES FLUE

HTDM 200 0 (0) 0 (0) 0 (0) 3(76) 0 (0) 18(457)
HTDM 400 6(152) 6(152) 4(102) 3(76) 4(102) 18(457)

HTDM 600 6(152) 6(152) 4(102) 3(76) 4(102) 18(457)
HTDM 1000 6(152) 6(152) 6(152) 3(76) 6(152) 18(457)
HTDM 1500 6(152) 6(152) 6(152) 3(76) 6(152) 18(457)

All units installed on the floor has a minimum clearance of 3"
(76mm) provided by the base frames of each individual unit.

For service it is advisable to maintain a minimum 24' clearance on
the side opposite the controls side (note: not valid for the HTDM

200), and 42" clearance on the control side. If this unit is to be
operated within a confined space or within a building of unusually
tight construction, air for combustion and ventilation must be
obtained from outdoors or other spaces freely communicating with
the outdoors. Refer to current United States and Canadian Fuel
Codes.

5

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. When such vapours mix with products of combustion, highly
corrosive compounds result, which will result in the premature
failure of the heat exchanger and other components. In such an
event the warranty is void.

CONNECTING THE FLUE (VENTING)

When making flue connection to the unit, observe the following
general recommendations. In addition, the HTDM series ofunits are
approved and must use recognized type "8" vent and/or vent
connector. All connections must conform to the requirements of
current United States and Canadian codes (gas fires units), and be
in accordance with local authorities, which include but are not
limited to:

a) The flue must be securely attached to the unit with tight

joints.

b) The pipe from the unit to the flue should rise at least If.."

per foot, (76.2 mm).

c) The flue must be sized to have a cross-sectional area not

less than that of the flue collar at the unit.

d) Other appliances must not be connected so as to vent through

the flue of this unit.

e) Do not support the weight of the stack on the flue connection

of the heating section.

f) Minimize connecting pip length and the number of bends by

locating the unit as close to the flue pipe as possible.

g) Maintain clearances between the flue pipe and combustible

material that are acceptable to the local authorities having
jurisdiction.

h) For indoor/outdoor application the flues condensate deposal

pipe, located on the unit, shall be piped to prevent
accumulation of condensate on or around the unit.

The HTDM series are approved for use with type “B” venting. The
venting must be of recognized type. For type “B” vent use with
the HTDM 1000 and HTDM 1500 models a draft hood must be
connected in series with the type “B” vent. The Drafthood must

6

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.
e) If a space thermostat is used with the furnace, locate the

thermostat so the cold drafts and hot discharge air streams

do not affect the performance of the unit. Do no mount the

thermostat on the casing of the unit, as it will be affected

by radiated and conducted heat. Refer to the instruction

furnished with the thermostat for further details.
f) If any of the original wires as supplied with the unit must

be replaced, it must be replaced with type TEW 105 degrees or

its equivalent except where noted.
g) Temperature controllers, limit controllers, remote selector

switches, door switches or any other auxiliary electrical

items must be connected to the terminals provided as shown on

the wiring diagram.
h) For units shipped in multiple sections, electrical

connections between sections are to be made by the installer

in the field.
i) Field wiring to be done by the installer is denoted by doted

lines on the wiring diagram. Solid lines on the wiring

diagram indicate factory wiring by the manufacturer.
j) The unit must be electrically grounded in accordance with

local codes, or in the absence of local codes, with the

National Electrical Code, ANSI/NFPA 70, and/or the CSA.C22.1

Canadian Electrical code.

NOTE: Due to the nature of transport check all bolts and
fasteners for tightness.

GAS PIPING

All gas piping should be in accordance with NFPA, National Gas
Code, and CAN 1-B149 with the regulation of local authorities
having jurisdiction. An emergency manual shut down valve shall

7

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.
d) A minimum 1/8" NPT plugged tapping, accessible for test gauge

connection, must be installed immediately upstream of the gas

supply connection to the appliance.

GAS VENT

High gas pressure regulator (if required), low pressure
regulator, pilot pressure regulator, gas pressure switch (if
supplied), and normally open vent valve (if supplied) must be
vented outside of building for an indoor unit (check with
authorities having jurisdiction).

DUCT FURNACES

a) A duct furnace shall be installed with an inlet duct, which

will provide air distribution equivalent to a straight run of

duct having the same cross-section area as the inlet

connection and not less than two equivalent diameters in

length.
b) The ducts connected to the duct furnace must have removable

access panels on both upstream and downstream sides of the

duct. The opening must be accessible, and shall be of such

size, that smoke or reflected light may be observed inside

the casing to indicate the presence of leaks in the heating

element. The cover for the opening shall be attached in such

a manner as to prevent leaks.
c) The installation of the duct furnace must be adjusted to

obtain an air throughout within the range specified on the

appliance rating plate.
d) If a duct furnace is connected to a return air duct or any

other inlet air restoration; the duct furnace shall be

installed on the positive pressure side of the air-

circulating blower.

8

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.

GENERAL OPERATING INSTRUCTION

a) Refer to the rating plate for fuel input and supply

pressures.
b) Do not attempt to start the burner if the unit is full of

vapour gas, or if the combustion chamber is very hot.
c) Do not leave combustible material near the unit.
d) Shut off the manual fuel supply valve if the burner has been

shut down for an extended period of time.
e) Ensure clean-out doors are in place before starting the

burner.
f) Do not start the burner unless the blower access doors are

securely in place.
g) Refer to literature regarding controls, gas valves and other

components.

START-UP PROCEDURES

1. PRECAUTIONS

a) Ensure the main disconnect switch is in the “off”

position.
b) Ensure the burner on-off switch is in the “off” position.
c) Check all electrical and gas connections and tighten if

necessary
d) Check main fans (by rotating fan shaft by hand), bearing

set screws, and pulley set screws. Ensure blowers are free

to turn, vibration isolation shipping blocks are removed

(if equipped), shipped loose items (if supplied), are

removed from inside blower sections.

9

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.
j) Check building system gas supplies and be sure all lines

are purged of air.
k) Check building system gas supply pressure.

2. CAUTION-GAS UNITS

At maximum input the supply gas pressure must fall within the
range specified on the unit rating plate.

a) Check all piping for tightness and correct any signs of

leaks.

b) Ensure purge timer is set to 70 seconds.

3. START-UP

a) Refer to start-up check list and field report for correct

settings that are to be checked on the unit.

b) Check the supply fan motor thermal overload setting against

the rating plate figure.
c) Ensure burner on-off switch is in the “off”
d) Verify units sequence of operation corresponds to sequence

provided in the supplied literature.
e) Check supply fan motor amps against rating plate figure. If

actual figure varies by +/-20% from rating plate value, take

corrective actions with respect to duct work and accessories

external to the unit or blower/motor drive adjustments making

sure to follow manufactures rating for blower rotational

speeds.
f) The thermal overloads must be set to appropriate motor

performance after all adjustments have been make.
g) Follow sequence and perform necessary steps to intiate burner

activation.
h) Once flame is detected the controller goes into "Power" and

“Heat” mode.
i) Check unit performance as described on the factory test

report, (include items such as stack temperature. CO-2 level,

10

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.

MAINTENANCE

Regular maintenance is necessary to ensure the efficient operation
and long life of this unit. This maintenance should be preformed
by or supervised by qualified service personnel. A maintenance
schedule should be prepared for the unit based on its application
and location.

1. RECOMMENDED OUARTERLY MAINTENANCE

a) Check for loose connections in the wiring.
b) Check the voltage at the unit while it is in operation.
c) Check motor amperage draws against rating plate values.
d) Inspect all contractors to ensure that they are clean and

making good contact.
e) Check all fittings valves and lines for leaks.
f) Check for proper combustion. Adjust if necessary.
g) Check the flame sensor signal (1.5-6.0 mA), clean if

necessary.
h) Check the fuel supply pressure to the unit.
i) On gas fired units check the manifold pressure.
j) Clean or replace air filters if necessary. Replace filters

only with type equivalent to those supplied with the unit by

the factory.
k) Check all dampers, linkages and damper actuators; adjust and

tighten as required.
l) Check all belts. Adjust or replace as necessary.
m) Check all bearings and lubricate if necessary.
n) Check operation of all safety controls.

11

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. clean and replace

if necessary.
f) Inspect and clean the collection and disposal systems to

ensure proper drainage.

NOTE: If ignition controller is replaced ensure the control
system is not exposed to water spray, rain or dripping water.
Refer to individual manufacturer’s literature provided for
maintenance requirements of optional equipment.

Power Venter Installation

The HTDM series may be equipped with a power vent system. Whnre
installing ensure that the factory supplied diverter box is
install on the unit, in series with the power venter.

a) Diverter box relief opening must be installed 10” from walls

and restrictions.

b) Mount power venter in desired location. NOTE: Refer to

manufactures installation instructions for vent length and

sizing.
c) Power venter must operate for the individual unit only.
d) Wire power venter and safeties according to supplied diagram.
e) Verify all safeties. In the event of venter failure the

burner must become in active.

NOTE: For venting diagram see Appendix C.

12

ICECON II

OPERATORS MANUAL

13

I. ICECON2 CONTROLLER

Figure 1

14

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.

2) Trial for Ignition

Upon timing out the combustion blower drops to low speed and the
ignition controller is powered. The pilot line solenoid is
powered opening the pilot gas flow to the burner. Simultaneously
the ignition controller initiates spark. . Upon proof of flame
ignition controller opens the main gas valves allowing gas to flow
to the modulating gas valve, simultaneously sending a 24VAC signal
to the ICECON2 controller. Upon receiving the 24VAC signal the
board will enter System Preheat.

3) System Preheat

System preheat is indicated by a flashing Heat Mode LED. During
this stage the ICECON2 controller will ramp the firing valve and
combustion blower to midrange without energizing the main supply
fan. Preheat lasts approximately 60 seconds. Upon completion of
the system pre-heat the main supply fan energizes and the unit
will begin to operate in one of the following modulation modes

III. HEAT MODES

1) Factory Set Discharge Temperature, no field adjustment.

The unit will adjust the firing rate to maintain the factory set
discharge temperature. The Power, Heat Mode and Auto LEDs are
illuminated to indicate this condition.

2) RTS (Remote Temperature Selector)

There are two temperature ranges for the RTS’, 40-90F and 90-120F.
The unit will modulate to maintain the temperature selected on the
RTS.

15

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.

The BMS supplier must supply the ICECON controller with either 0­10 VDC or 4-20 ma signal. The signal is to be supplied to
terminals J25 and J26. After normal startup sequence is finished
the auto led will remain de-energized. The unit will now only
respond to the BMS signal and is unable to self adjust to changes
in conditions.

The ICECON II controller will respond to the incoming signals and
modulate to a corresponding firing rate. The firing curve is
composed of discrete steps. Each step is controlled by a trigger
voltage or current that once reached the combustion will move to
the next combustion step. When tuning a the BMS system the
following points must be consider:

How the ICECON II Controller Responds to External Modulation
Control

The ICECON II controller automatically scales the incoming signal
to the internal combustion curve that has been programmed at the
factory. The curve is made of discrete steps. There are dead­bands in the signal in which the unit will not modulate with an
increase or decrease in the control signal.

Once a signal is received the controller will modulate to the
corresponding firing point. During this transition the ICECON II
controller will not respond to changes in the control signal. As
a result the Control system must be tuned for a very slow
response. Poor temperature control will result if the system is
not tuned correctly.

16

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.

17

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.

2) Low Limit

The unit will shut down the supply fan if the duct temperature
falls below the factory set point.

3) System Preheat

The unit can use a built in time delay before the contacts to the
main supply fan are energized. This will allow a preheating of
the heat exchanger to insure that only warm air will be supplied
to the space.

Preheat operation begins with a normal trial for ignition. Once
flame has proven the unit will modulate to the midpoint of the
firing range. The heat mode led will indicate the preheat cycle
by flashing. The unit will remain at the midpoint until the
preheat cycle is ended. Once ended the main supply fan contacts
will energize and normal heat mode operation will begin.

4) Standby mode

Standby mode is to be used in conjunction with an on/off
thermostat or when periodic heating is required. In Standby mode
the ICECON2 is continually powered. The unit will indicate
standby mode by flashing the power LED. In this mode the heat
cycle will remain powered down until there is a call for heat from
indicated by a 24VAC signal on terminal J22. Upon a call for heat
a normal start up sequence is ran and the unit will then enter
heat mode. Once the call for heat is satisfied and the 24VAC
signal is lost on terminal J22 the ICECON2 controller will exit
heat. The unit will enter a post heat purge. During this time
the combustion blower and firing valve are ramped to full fire.
Upon completion of the post heat purge the burner and combustion
blower are shut down. The main supply fan will remain in

18

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.

19

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. The main supply blower will
remain energized until the duct temperature falls below the
factory set safe shut down temperature. The combustion blower
will remain at max RPM until the unit is reset.

2) Low Limit Error

The low limit lock out condition occurs when the air temperature
in the duct work has fallen below a factory set position. This
condition is indicated by the illumination of LED numbers 5, 6 and

7. Upon a drop in duct air temperature the unit will lock out and
shut down the burner. The main supply fan will be de-energized to
stop the flow of unheated air form entering the space. The
combustion blower will run at the max RPM setting.

3) Air Proving Error

Air proving error occurs when the tachometer stops sending a
signal to the ICECON2 controller. This condition is indicated by
the illumination of LED numbers 5 and 6. The fan operation must
be checked as well as the function of the tachometer sensor
itself. Improper operation will cause poor and irregular
combustion. The unit must be reset to reinitiate.

4) Flame Error

Flame error occurs when the flame signal is lost to the ICECON2
controller. Lock occurs after the fourth attempt during trial for
ignition and in any instance in which flame is lost after heat
mode has been achieved. The unit must be reset to reinitiate.

5) Valve Error

Valve error occurs when the ICECON2 controller looses
communication with the modulating gas valve or abnormal operation
of the modulating gas valve has been detected. This condition is

20

indicated by the illumination of LED numbers 5, 6 and 8. The unit
will lock out and will require resetting to reinitiate.

21

V. Trouble Shooting

reading above the factory set

Check main blower and dampers

• The ICECON2 controller has

AIR PROVING ERROR

FLAME ERROR

HIGH LIMIT 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.

• Check gas supply

• Check ignition module for

proper operation

• Check all fail safes for

proper operation

• Check valves, manual and

solenoid, for proper
operation

• Check ICECON2 fuses

• The ICECON2 controller has

received a temperature

LOW LIMIT ERROR

VALVE ERROR

value.

•

for proper operation.

• Check discharge sensor for

correct attachment. Open
contacts on the Discharge
sensor terminals will cause
indication of a high limit
condition.

• Check ICECON2 fuses

• The ICECON2 controller has

detected a temperature below
that set by the as the low
limit.

• Check unit for proper

operation.

• Check discharge sensor.

Continuity between the white
and black terminals will
return a –51 degree F signal.

• Check ICECON2 fuses

22

10VDC) on

ICECON2 requires 24VAC on terminal J12

ICECON2 controller. If power is trace

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-

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. Check fuses on both
the control panel and Circuit board
and replace as necessary.

• Verify correct wiring, wiring

connections and grounding of the
electrical components.

•

to enter heat mode.

• Board requires a 2.0 VDC signal on

terminal J11 before initiating trial
for ignition.

• Flame has not proven. ICECON2

requires a 24VAC signal on terminal
J22 before entering heat mode. The
controller will use 4 trials for
ignition before indicating “flame
error”.

• Check for free rotation of the

modulating valve

• Check for correct feedback signal

• Check for power on terminal J5 on the

unit wiring as per diagram to
determine fault.

• Check for power on terminal J6. If

power is not present trace wiring as
per diagram to determine fault.

• If power is present on J6 but not J5

the system is not calling for the
supply air.

23

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.

The tachometer sensor is polarity sensitive. Improper operation
can be caused from improper orientation of the magnet. If
problems continue remove and reverse the magnet and repeat the
above procedure

New Style Tachometer Test (Equipped on unit built in 2000-present)

Disconnect power to the combustion blower. Engage a heat cycle so
that the board locks out on an air proving error.

• Verify approximately 5 VDC between terminals J2-17 and J2-18.

If voltage is not present disconnect all tachometer leads
from the board and recheck. If power is now present replace
the tachometer and verify wiring is correct. If power is
still absent replace the ICECON II controller and verify
wiring.

• Ensure that the magnet is not aligned with the end of the

tachometer. Approximately 5Vdc should be between J2-18 and
J2-16.

• Rotate the combustion blower wheel until the magnet is

aligned with the tachometer. The voltage between J2-18 and
J2-16 should now be zero. If this is not the case check the
distance from the tachometer and the magnet. This space
should not exceed 1/8th of an inch. If required adjust to the
correct spacing. If the systems remain the same the magnet
will have to be remove and reversed as the tachometer is
polarity sensitive.

24

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”. “Read” performs a
one-time read of the variables. “5 second read” performs a read
function every 5 seconds. “Exit” closes the I/O screen. Click
the “5 second read” button.

Compare the value of the discharge sensor reading with a know
temperature. At this time if a discharge reading of 281°F is
displayed there is an open circuit in the discharge sensor circuit

and the unit will lock out on “High Limit Error”. The discharge
sensor reading should be stable with less than 1-2° fluctuations at
steady state conditions.

Turn the RSP counter clockwise until the physical stop is reached.
A value of 40 when a 40-90°F RSP is being used and 90 when a 90­120°F RSP is used should be displayed in the RSP value (This may
take up to 30 seconds).

Turn RSP clockwise until the physical stop is reached. The upper
limit of the RSP should be displayed. Verify a mid point and
align the pot to the correct temperature scale position. To do
this, use a small screwdriver to loosen the knob and reposition
such that the arrow points to the correct temperature. Retighten
the knob.

The low temperature scale should have an ohm range of 0-5000Ω
resistance range. The High temperature range RSP should have
100kΩ-200kΩ resistance range.

25

VII. Wiring

Modulating gas valve ground (24VAC

J1 24VAC Neutral
J2 24 VAC
J3 Normally open contact to purge

timer coil
J4 24VAC for purge timer common
J5 Normally open contact to supply

fan
J6 24VAC for supply fan common
J7 Solid State Relay (+ VDC)
J8 Solid State Relay (-VDC)
J9 Modulating gas valve control

signal (2-10 VDC)
10

common)
J11 Modulating gas valve feedback

signal (2-10 VDC)
J12 Heat mode/Standby (Switched 24VAC)
J13 Temperature sensor ground (-VDC)
J14 Temperature sensor supply (+5VDC)
J15 Temperature sensor signal (+VDC)
J16 Tachometer sensor signal (+VDC)
J17 Tachometer sensor supply (+5VDC)
J18 Tachometer sensor ground (-VDC)
1J9 Space Override contact
J20 System ground
J21 Space Override contact
J22 Flame detect in (24VAC)
J23 Remote Temperature Selector

Contact
J24 Remote Temperature Selector

Contact
J25 Building Management in
J26 Building Management in

26

Appendix A

27

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. This software can be identified by the
seven configuration check boxes in the top right hand corner of
the main screen. The original software only had 3 configuration
boxes.

Setting up the Software

To establish communication ensure that the ICECON II controller is
in either “Stand-By” mode (indicated by flashing power led), in
“Heat Mode”(indicated by both “Power” and “Heat Mode” leds
illuminated) or locked in an error condition

When first installed the program will not be configure to your
system. To properly configure the software you must chose the
correct COM port for the serial cable connection on your computer.
To begin activate the “Settings” pull down menu and select
“ComPort”. Select the COM port if known.

If the COM port configuration on you computer is not known you
must connect to an active ICECON II controller. Once this is
accomplished activate the “Settings” pull down menu and select
“ComPort”. Begin by selecting the initial COM port “COM 1”.
Allow 30-45 seconds for the software to communicate. If the board
continues to indicate “Board not communicating” then try another
COM port.

If communication cannot be established ensure that only one
application of the ICECON software is running. Check that the
correct communication cable is being used (9-pin, straight through
cable with gender changer) and is connected to both the computer
and ICECON II controller.

Once configured the software will store the correct COM port.
This procedure will only be necessary upon initial installation of
the software.

28

points from which the firing

the combustion curve.

programmed. Changing these will effect

the required inputs and outputs of the

unit.

values that effect the system

response time and accuracy.

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.

Check boxes control which factory set

Kp and Ki are factory set control

options have been selected and

Factory Set Discharge
Temperature

Factory Set High Limit

Factory Set Sae Shut Down

Factory Set Low Limit

Displays all six combustion

curve is calculated.

Displays the corresponding
RPM value for each point of

Figure 2

29

System Tune Interface

When highlighted this

will proceed to the

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. Each
point must increase in value or the
system will lock out in set up error.

previous point.

The valve box allows for the
adjustment of the valve/gas
flow at the set point in
question. The value indicated
in this box will be the output
voltage to the modulating gas
valve.

When selected the
program will move
to the next point.

Sends displayed values to
the ICECON controller.

Figure 3

30

I/O View

detect provide information

indicates normal operation

while OFF

loss of signal.

High Limit, Low Limit and

The READ option will do a one

5 SEC READ

will perform a real time

The bottom four values

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.

Ini Error indicate improper

Air proving and flame

on the combustion blower
and flame signal. ON

will confirm a

display the current
values of fan speed, valve
voltage, discharge
temperature and RSP.

Figure 4

operation of the unit. Off will
indicate normal operation will
ON signal a lock out
condition has occured.

time real time read of the sytem
operation at that time.

read every five seconds after it is
initiated.

ICECON II Configuration

The main configuration for the board is contained in the seven
check boxes located in the top right corner of the main screen.

1. ByPass System Preheat. Once checked the preheat cycle will

by eliminated. The preheat cycle will take place once main
flame has been established. The burner will be ramped to a
mid point in the firing range and remain there for
approximately 45 seconds. Once complete the output on J1­5(usually used to energize the supply fan) will be energized.
The ICECON II controller is now ready for modulation.

2. RSP. Once checked the ICECON II controller will look for a

remote temperature dial for the temperature set point. The
remote temperature dials are available in two ranges 40–90°F
and 90-120°F. This is only used during standalone operation
and cannot be used when a building management system (BMS) or

other source is being used to provide the modulation control.
When not checked the ICECON II controller will maintain the
temperature indicated in the “Discharge Temperature” set
point box.

31

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. To enter a
heating cycle 24 Vac must be present on terminal J2-12. When
not checked board is only to be power during a heating cycle.

6. System Fan on in Standby. Once checked the output on J1-5

will be energized in both “Standby” and “Heat” modes. A
delay will be experienced during transitions between the two
modes.

7. Low Limit. When checked the low limit sensing routines are

energized. During “Heat Mode” if a temperature is sensed
below the low limit set point the J1-5 output will be
deenergized. The is a non-adjustable 3-minute delay upon
initiation of a heat cycle.

Set Points

Located beneath the ICECON logo are six set points. They are as
follows:

1. Discharge Temperature. This box is used to introduce a

positive offset from the RSP set point. It is used for
calibration of the discharge sensor and in the event that no
RSP is being used will indicate the temperature to be
maintained.

2. Upper Limit. This temperature is the set point at which the

ICECON II controller will de-energize J1-3 (Burner on output)
to shut off the heat when the discharge sensor detect any
temperature above this value. Once this has occurred the
unit will indicate “High Limit Error”.

3. Safe Shut Down. Upon tripping on a “High Limit Error” J1-5

(Supply fan output) will remain energized until the discharge
sensor detects a temperature below this set point.

4. Kp. This is used for controlling the aggressiveness of the

temperature response. The higher this value the faster the
response and greater chance of temperature overshot. The
default value is 70.

5. Ki. This is used to control the temperature response and is
an error multiplication factor. The default is 2.

32

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. This number will determine the speed at
which the combustion fan will rotate when firing at the
corresponding firing point.

The fan rotation speed is indicated by the “RPM” box. This value
is read in from the tachometer sensor as the combustion points are
configured. This value is used by the software as a reference to
ensure that the correct fan speed is maintained. Once configured
the RPM values must maintain a 200-rpm separation between points
and increase as you move from left to right across the screen.

The “Valve” box contains the valve set points. This will
represent actual DC voltage being sent to the modulating gas
valve. These points must increase as you transition form left to
right across the main screen. The valve functioning range is 2 to
10 VDC.

Altering Combustion Set Points

Calibrating the Tachometer

Before altering any points the main firing valve should be
switched to the closed position. When adjusting combustion points
it is possible to override the internal stepping functions.

To begin setting up the combustion curve access the “Tools” pull
down menu and select the “System tune” function. This gives
direct access to the combustion curve set points. The first point
(low fire) is displayed. To override the system and force the
system to low fire press the “Send” button. The combustion fan
will adjust to the appropriate speed and the modulation gas valve
will track to the correct voltage. It is important to notice that
the valve voltage does not correspond to the voltage that was
displayed on the main screen, it is in fact double. This is just
how it is at this time so live with it. When the main screen is

33

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. Repeat the process until the high fire set point is
reached. Press “Exit” to return to the main screen. After a few
second the system will update the combustion points and the
updated tachometer readings will be displayed.

Adjusting Combustion Points

The following tachometer and valve set points provide a rough
guideline.

Point #1: 1200-1800 rpm, 2.5Vdc (5.0Vdc in system tune)
Point #2: 1800-2200 rpm, 3.5Vdc (7.0Vdc in system tune)
Point #3: 2200-2500 rpm, 4.5Vdc (9.0Vdc in system tune)
Point #4: 2400-2700 rpm, 5.5Vdc (11.0Vdc in system tune)
Point #5: 2600-3000 rpm, 6.5Vdc (13.0Vdc in system tune)
Point #6: 3000-3400 rpm, 8.0Vdc (16.0Vdc in system tune)

It is very critical to maintain a minimum 200rpm separation
between combustion points. Once this rough curve has been
established override this system to high fire. Open the firing
valve and set the manifold pressure. Shut the firing valve and
force the system to low fire. Reopen the firing valve when the
system is at low fire. Walk the system through each point in the
combustion curve and check combustion making adjustments to the
gas valve voltage as necessary. Once complete exit system tune
and recheck complete curve. If the curve is satisfactory press
the “Write” button. Confirm that the program has been updated by
clicking the “Read” button.

High fire should be running between 5-7% oxygen, 7-9% CO2 while at
low fire that number will vary from 18-20% oxygen, 0.1-1% CO2.
Remember as the dirt accumulates the combustion fan performance
will drop off so allow excess oxygen during initial factory set
up.

34

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).
Click the save button and the file has been saved. This should be
done whenever working on a unit that has been in operation and
should be used as a base line for adjustments.

Uploading a ICECON II File to a Controller

Connect the computer to the ICECON II controller and establish
communication. At this time the program that has been stored in
the controller will be displayed. To load an existing program
open the “File” pull down menu and click the “Open” function.
Locate the file to be loaded and select it. At this time the
program to be loaded is displayed on the ICECON interface screen.
To upload this to the board click the “Write” button. This will
overwrite the information stored with the program displayed on the
interface. To confirm that the information has been uploaded
press the “Read” button and the stored information will be
displayed. Some programs may not be compatible and will cause the
“Board not communicating” to be displayed. Try an alternate
program.

Error Codes of the ICECON II Controller

1. High Limit Error. The high limit error will occur when the
discharge sensor detects a temperature above the upper limit

set point. A false high limit trip can occur when the
discharge sensor in not connected, as an open circuit in will

default the temperature reading to 281°F. This is
characterized by the system entering heat cycle, purging,
lighting and approximately 5 seconds after main flame has
proven, locking out on high limit.

2. Low Limit Error. This occurs when the discharge sensor
detects a temperature below the low limit set point. A false
reading can be created if there is continuity (i.e. a dead
short) between terminals J2-13 and J2-15. In this case the

35

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. Flame Detect Error. If the ICECON II controller has not
detected a flame (i.e. receiver a 24Vac signal on terminal
J3-22).

6. Setup Error. This error occurs when the Combustion points
have been incorrectly configured.

Figure 5

36

Appendix B

37

ICECON1 to ICECON2 Upgrade

Purple wire from 10 pin

Yellow wire from 10 pin

Orange wire from 10 pin

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. Remove the end connector of the 10 pin connector and expose the
individual wires (approximately 3 inches).

6. Strip ends of individual wires exposing approximately ¼ inch of
wire.

7. Attach wires according to the following diagram

Termin
al
J1-1 24 VAC Neutral on

J1-2 Red wire from 10 pin

J1-3

J1-4 Grey wire from 10 pin

J1-5

J1-6

J1-7 White wire from 10 pin

J1-8 Blue wire from 10 pin

J1-9 Black wire from 10 pin

J1-10 Brown wire from 10 pin

8. Completely remove the 6 pin connector from the control panel.
Use the sensor leads to wire into the ICECON2 Controller for the
following connections.

Connect to

control panel

connector

connector

connector

connector

connector

connector

connector

connector

connector

38

Terminal Connect to
J2-1 Feedback from actuator

(0-10VDC)
J2-2 Not used
J2-3 Black wire from

discharge
J2-4 Red wire from discharge
J2-5 White wire from

discharge
J2-6 *Black wire from

tachometer
J2-7 *Brown wire from

tachometer
J2-8 *Blue wire from

tachometer

Option 1

*Note: If equipped with a discharge sensor with red, white and
black wire leads see option 2.

Terminal Connect to
J2-1 Feedback from actuator

(0-10VDC)
J2-2 Not used
J2-3 Black wire from

discharge
J2-4 Red wire from discharge
J2-5 White wire from

discharge
J2-6 White wire from

tachometer
J2-7

Red wire from tachometer

J2-8 Black wire from

tachometer

Option 2

9. Remove the end connector of the 8 pin connector and expose the
individual wires(approximately 3 inches).

39

10. Strip ends of individual wires exposing approximately ¼ inch
of wire.

11. Attach wires according to the following diagram

Termin
al
J3-1 Not used
J3-2 Red from 8 pin

J3-3 Green from 8 pin

J3-4 Yellow from 8 pin

J3-5 Brown from 8 pin

J3-6 Orange from 8 pin

J3-7 Blue from 8 pin

J3-8 Black from 8 pin

Connect to

connector

connector

connector

connector

connector

connector

connector

40

J1 Connector

J2 Connector

J3 Connector

41

Appendix C

42