Heatcraft intelliGen H-IM-iRC Manual
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Heatcraft intelliGen H-IM-iRC Manual

Heatcraft intelliGen H-IM-iRC Manual

Refrigeration controller
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intelliGen
Refrigeration Controller
H-IM-iRC
February 2025
Part No. 25009901
Installation and

Table of Contents

Operation Manual
intelliGen Components
intelliGen Board (iRC) Layout ................................ 2
Installation & Wiring
Installation Tips .................................................... 4
Evaporator Unit ................................................... 4
Condensing Unit by Others .................................. 5
Refrigerant Line Brazing ...................................... 5
Leak Testing ....................................................... 5
Refrigerant Charging ............................................ 6
Wiring .............................................................. 6-8
Wiring Terminals .................................................. 9
Wiring Diagrams ...........................................10-22
Installation Checklist ......................................... 23
Start-up & Operation
Check-Out Installation ........................................ 24
Initial Power On ................................................. 24
System Start-up ............................................... 25
Cooling Start-up Operation ............................... 25
Home Menus & PIN ............................................. 26
Navigation, System & Local .............................. 26
Menus and Settings .....................................27-33
Cooling Sequence of Operation .......................... 34
Defrost Sequence of Operation ............................ 35
Special Features Operation ...........................36-38
Service Record Checklist ................................... 39
Preventive Maintenance ..................................... 40
Webserver Card (iWC) ...................................... 41
Integration Card (iIC) .......................................... 42
Light Bar, Alarms & Error Indicators .................... 43
Monitoring Items & Test Mode ........................... 43
Power Failures .................................................. 44
Checking Temperature Sensors ........................ 44
Evaporator Temperatures ...............................46-47
Replacing Carel EXV's ........................................ 50
Replacing iRC Board ........................................... 51
Scan QR code to view the
Replacing iRC User Interface .............................. 52
manual online
Special Tips ....................................................... 58

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Summary of Contents for Heatcraft intelliGen H-IM-iRC

  • Page 1: Table Of Contents

    Installation & Wiring Installation Tips ............ 4 Evaporator Unit ........... 4 Condensing Unit by Others ........5 Special Condensing Unit by Heatcraft ....5 Refrigerant Line Brazing ........5 Leak Testing ............5 Refrigerant Charging ..........6 Wiring .............. 6-8 Wiring Terminals ..........

  • Page 2: Intelligen Board (Irc) Layout

    Communication Connection Power Temp Supply Suction Temp iRC-UI Coil Connection Temp Suction Pressure Chasis Ground Grounded Grounded Mounting Mounting Screw Screw Condensing Unit Connection Evap Temp Product Load Spare I/O Communication Switch Door Switch Connection © 2025 Heatcraft Worldwide Refrigeration...

  • Page 3: Intelligen User Interface (Ircui) Layout

    intelliGen User Interface (iRCUI) Layout Status Light Bar OLED Display Return Favorites Button Button Home Button Control Button intelliGen Remote Access Cards MULTI-SYSTEM CONTROL CARD - MSC INTEGRATION CARD - iIC WEBSERVER CARD - iWC Wi-Fi Direct Antenna* Wiring Terminal Scan the QR code or visit www.

  • Page 4: Installation Tips

    The intelliGen control has compressor short cycle protection functionality built-in, and failure to remove the • There are built-in ground connections on the Heatcraft electro-mechanical ASCT relay can result in system run-time intelliGen Refrigeration Controller (iRC) board’s four corner conflicts and negative impacts to system performance.

  • Page 5: Condensing Unit By Others

    VERY IMPORTANT: If the supply voltage to the evaporator is 208 volts, the The special Heatcraft condensing unit control panel contains primary tap of the transformer must be moved to the 208 volt the relays, compressor contactor, time delay and a terminal tap.

  • Page 6: Refrigerant Charging

    Installation Refrigerant Charging The special HRP condensing units are shipped standard with a head pressure control valve. The maximum system refrig- erant capacity is the receiver capacity as listed in the sales literature plus the liquid line capacity. Do not add more refrigerant to the system than 90% of the receiver capacity unless the line run exceeds 25 feet.

  • Page 7: Wiring

    Installation Wiring (cont.) Access to iRC board for wiring varies by evaporator style. Below are the examples of how to access. All iRC boards are mounted on the piping or header end of the evaporators. Low Profile Evaporators Hinged Bracket For iRC UI To access to iRC board: 1.) Remove side panel (take care to not damage iRC...
  • Page 8 Installation Wiring (cont.) • Low voltage - 24V Class II control circuit. A total of two • All wiring must comply with all applicable local and na- low voltage leads are required to connect a special HRP tional codes, standards and ordinances. condensing unit to an iRC evaporator.

  • Page 9: Wiring Terminals

    Installation Wiring Terminals • Bottom iRC board terminals to the right are those which will be wired in the field. Not all of them are available at this time, and not all of them will be selected for use on the job.

  • Page 10: Wiring Diagrams

    Wiring Diagrams Field Wiring Options Aux Temp Sensor Product Load Switch Service Switch...
  • Page 11 Wiring Diagrams Field Wiring Options NOTE: Door Switch can be configured for Normally Open or Normally Closed. Special HRP Condensing Unit Special intelliGen Condensing Unit Only NOTE: To use the Outdoor sensor as an aux temp sensor, wire OD TEMP to AI6 terminals of iRC...

  • Page 12: Humidity Sensor

    Humidity Sensor Heatcraft Supplied Humidity Sensor Relative Humidity Range: 0-100% Output: 0-10VDC Power: 24VDC Operational Temperature Limits: -40F to 140F Heatcraft Part Number: 22597901 Accuracy: +/-3% 20-80% RH @ 25C Drift: <1% RH/year Hysteresis: +/- 1% Repeatability: +/- 0.1% Typical Weight: 0.3 lbs...
  • Page 13 Wiring Diagrams EV COM WIRING CONNECTIONS: HEATCRAFT intelliGen | Refrigeration Controller Two evaporators on a single system (24 AWG 1-twisted-pair RS-485 shielded cable) A03 GND A03 GND A16 GND A16 GND 2 4 VDC 2 4 VDC 24VDC 24VDC A17 GND...
  • Page 14 Wiring Diagrams EV COM WIRING CONNECTIONS: HEATCRAFT intelliGen | Refrigeration Controller Four evaporators on a single system (24 AWG 1-twisted-pair RS-485 shielded cable) NOTE: For applications with more than one dual-board Large Unit Cooler (LUC), disconnect factory installed COM wire and reference Page 8 for proper wiring procedures.
  • Page 15 Wiring Diagrams REFRIGERANT DETECTION SYSTEM (RDS) COMMUNICATION WIRING CONNECTIONS: For A2L Refrigerant Unit Coolers with intelliGen (24 AWG 1-twisted-pair RS-485 shielded cable)
  • Page 16 Wiring Diagrams TYPICAL EVAPORATOR INTERNAL WIRING DIAGRAM ELECTRIC DEFROST AIR DEFROST...
  • Page 17 Wiring Diagrams LARGE UNIT COOLER EVAPORATOR RDS COM MEDIUM PROFILE EVAPORATOR RDS COM...
  • Page 18 Wiring Diagrams TYPICAL GENERIC CONDENSING UNIT WIRING DIAGRAM FOR intelliGen STAND-ALONE EVAPORATOR CONTROLLER...
  • Page 19 Wiring Diagrams CONVENTIONAL CONDENSING UNIT WIRING CONVERSION FOR INTELLIGEN STAND-ALONE EVAPORATOR CONTROLLER This Wiring is to be removed or disabled when installing This Wiring is to be removed or disabled when installing...
  • Page 20 Wiring Diagrams CONVENTIONAL CONDENSING UNIT WIRING CONVERSION FOR INTELLIGEN STAND-ALONE EVAPORATOR CONTROLLER TDR to be bypassed or removed when installing This Wiring is to be removed or disabled when installing Must have Separate Power Supply TDR to be bypassed or removed when installing To be removed or disabled.
  • Page 21 Wiring Diagrams 24 VOLT CONNECTION WIRING - HEATCRAFT CONDENSING UNIT CONDENSING UNIT WITH ONE EVAPORATOR A03 GND A16 GND 2 4 VDC 24VDC A17 GND 2 4 VDC A18 GND EV COM EV COM COMP COMP 24VAC 24VAC 24V RTN...
  • Page 22 Wiring Diagrams TYPICAL intelliGen CONDENSING UNIT WIRING...

  • Page 23: Installation Checklist

    • Are Suction lines fully insulated? • Check system for refrigerant leaks. Are there any leaks on the SETTINGS COOLER, FREEZER, CONDENSING UNIT or INTERCONNECTING • Check Heatcraft intelliGen Refrigeration Board settings for PIPING? the following: FREEZER • Check system piping for unusual vibration or noise. Is there...

  • Page 24: Equipment Startup

    Equipment Startup Check-Out Installation (g) All fan motors on air cooled condensers, evapora- After the installation has been completed, the following tors, etc. should be checked for proper rotation. points should be covered before the system is placed in Fan motor mounts should be carefully checked for operation: tightness and proper alignment.

  • Page 25: System Start-Up

    Equipment Startup System Start-up When the system is initiated for the first time, the compres- When the room thermostat setting is satisfied (which may sor and the electric defrost evaporator fans will be in a take a considerable amount of time on “hot-box” pulldown), hold-off cycle and will not start unless the hold-off cycle is and if the compressor has run for a minimum time for the complete.

  • Page 26: User Interface Navigation

    User Interface Navigation Home Menus Navigation The QUICK SETUP inputs only appear when the system is To navigate to other menus, turn the Control Knob on the first initialized and will NOT appear on iRC UI for any other iRC UI until the menu desired is displayed. Then press the system starts.

  • Page 27: Monitor Menu

    Monitor Menu In this menu, you can review the current status of most critical system parameters. Parameter/Measurement Range BOX TEMP -40°F to 125°F BOX TEMP SP -30°F to 60°F SYSTEM NAME 20 characters of text EV UNIT NAME 20 characters of text BOX RH 0% to 100% RH OPERATING MODE...

  • Page 28: Alarm Menu

    System Running * The pressure transducer setting for 28911201 (139.7PSIA) is used for retrofitting Heatcraft's legacy Beacon II and QRC systems to intelliGen. Typical factory mounted intelliGen systems use 28911202 (300PSIA) transducer. ** The SERVICE SWITCH INPUT selection menu is not showing on local user interface when a Webserver Card or Multi-system Control...
  • Page 29 Superheat Control Menu In this menu, you will be able to set your design, desired operating superheat (at the evaporator) and also set the minimum superheat value which will trigger an error if any iRC operates for 2 minutes below this value. Parameter/Set-Point Defaults are Dependent on Defrost Type Change...
  • Page 30 EV Fan Menu In this menu, you will be able to set your fan control parameters. Parameter/Set-Point Defaults Range Type Change Mode EVAP FAN CONTROL STYLE Standard Standard, Two Speed, Variable Local Service EVAP FAN STIR ENABLE On, Off Local Service EVAP FAN STIR CYCLE FREQUENCY 12 min...
  • Page 31 Connectivity- IP Address & Submask In this sub-menu, you can view and set IP parameters for web based connections. Parameter/Set-Point Defaults Range Type Change Mode ETHERNET MAC ADDR Read-Only 12 digit hexadecimal System CONFIGURE IPv4 DHCP DHCP, Static System Running User Defined (Set Automatically IPv4 ADDRESS 0.0.0.0 - 255.255.255.255...

  • Page 32: General Settings Menu

    General Settings Menu In this menu, you will be able to set your general system parameters. Parameter/Set-Point Defaults Range Type Change Mode TIME FORMAT 12 Hour Format 12 Hr, 24 Hr System Service COUNTRY User Defined US, Canada System Service TIME ZONE User Defined Various...

  • Page 33: Manual Menu

    Manual Menu In this menu, you will be able to set manual control parameters. Parameter/Set-Point Defaults Range Type Change Mode RESET ACTIVE TIMER Execute System Running RESET TIME System Running Off, EV Spare Relay, EV Fan Relay, EV Solenoid Relay, EV Alarm MANUAL RELAY MODE Local Service...

  • Page 34: Cooling Sequence Of Operation

    Cooling Sequence of Operation Anti-Short Cycling Provision Call for Cooling (System Controller) To minimize the problems associated with rapid, short cycling When there is a call for cooling, the current box temperature measurement is greater than the Box Temperature Set of the compressor, the intelliGen Refrigeration Controller ™...

  • Page 35: Defrost Sequence Of Operation

    Cooling Sequence of Operation Defrost Initiation Demand Defrost: Demand Defrost is the means of evaluating the magnitude When a defrost is initiated based on time of day, frost load of the frost load on the evaporator coil and initiating a de- magnitude or ‘forced’, the controller must first check that the frost cycle when the frost load has exceeded the minimum compressor has been on for the Minimum Run Time, then the...

  • Page 36: Special Features Operation

    Special Features Operation Updating Firmware Using USB USB Drive Support The intelliGen iRC board supports USB drive with storage Firmware updates to the intelliGen Refrigeration Controller board may be accomplished using a USB flash drive by capacity up to 32GB. The following brands of USB drives following the steps below: were tested compatible.

  • Page 37: Service Mode

    Special Features Operation Evap Auxiliary Temp – Optional Input Dual Defrost Sensors Termination In certain high humidity applications, if the default defrost This sensor may be used to measure an additional sensor cycle was not able to completely defrost the coil. Adjust such as a product simulator.
  • Page 38 Special Features Operation A2L Alarm and Alerts For A2L refrigerant unit coolers, a Refrigerant Detection System (RDS) is required in the unit cooler to detect refrigerant leaks and perform mitigation actions to meet regulatory requirement. intelliGen has the capacity to communicate with the RDS control board via RS-485 communication connection and provide A2L related alarm alerts and status reporting.

  • Page 39: Service Record Checklist

    ______°F/°C Freezer Compressor Amps ______L1 ______L2 ______L3 Freezer Discharge Pressure ______PSIG Freezer Suction Pressure @ Compr______PSIG @ Evap______PSIG Freezer Suction Temperature @ Compr______PSIG @ Evap______PSIG Freezer Refrigerant Charge ______lbs. of R-______ Freezer Discharge Temperature ______°F/°C © 2025 Heatcraft Worldwide Refrigeration...

  • Page 40: Preventive Maintenance

    Preventative Maintenance Evaporators All evaporator units should be checked once a month or more 4. Check all fan motors. Tighten motor mount bolts and often for proper defrosting because the amount and pat- nuts and tighten fan set screws tern of frosting can vary greatly. It is dependent on the coil 5.

  • Page 41: Remote Access Options

    Remote Access Mounting the Webserver Card (iWC) and Multi-System Control Card (MSC) To enable local and remote access to the intelliGen system, a Webserver Card or Multi-System Control Card may be mounted to the iRC. There is a row of pins protruding from the back and top of the card which must plug into sockets on the board located near the center of the board above the CPU (central processing unit) chip.

  • Page 42: Integration Card (Iic)

    Remote Access Mounting the Integration Card (iIC) To enable access to the intelliGen system through a Building Automation System, an Integration Card may be mounted to the iRC. There two rows of pins protrud- ing from the back and top of the card which must plug into sockets on the board located above the clock battery.

  • Page 43: Diagnostics & Troubleshooting

    Diagnostics & Troubleshooting Light Bar on iRC UI Errors (cont.) There are several different features available on the ER18: Aux Probe Temp intelliGen Refrigeration Controller to inform users of cur- ER19: Replace Battery R20: Log Disrupted rent system or local unit status or condition. The most ER22: UI Failure predominant feature is the light bar on the iRC UI which ER23: Board Comm...

  • Page 44: Power Failures

    Power Failures & Sensors Power Failures Aux Temp Sensor Terminals In the event of a power failure, intelliGen will automatically IntelliGen provides a set of input terminals for customers close the expansion valve to prevent refrigerant from mi- who may want to monitor an additional temperature or grating throughout the system.

  • Page 45: Checking Operation Of Expansion Valve

    Checking Operation of Expansion Valve Checking Operation Of Expansion Valve (EXV) The expansion valve position can be monitored from the OLED in To check if the expansion valve is closing properly: the “MONITOR” menu by scrolling to the “EXV STEP POSITION”. This will indicate the number of steps the expansion valve is open.

  • Page 46: Evaporator Temperatures

    Evaporator Temperatures Table 2. Evaporator Temperatures R-22 R-404A/R-507 Evaporator Temperature (°F) Evaporator Temperature (°F) 100 psi Pressure Drop 100 psi Pressure Drop 50839.25 PART NUMBER TONS BTUH TONS BTUH TONS BTUH TONS BTUH 29326101 0.44 5220 0.41 4920 0.73 8706 0.64 7692 29326201...
  • Page 47 Evaporator Temperatures Table 2. Evaporator Temperatures (cont.) R-454A R-454C Evaporator Temperature (°F) Evaporator Temperature (°F) 100 psi Pressure Drop 100 psi Pressure Drop 50839.25 PART NUMBER TONS BTUH TONS BTUH TONS BTUH TONS BTUH 29326101 1.33 15,994 1.22 14,627 1.20 14,369 1.07 12,865...

  • Page 48: Replacement Parts List By Interlink

    Replacement Parts List Replacement Parts by Table 3. intelliGen Field Mount (iFM) Kit and Accessories Description Part Number intelliGen Field Mount (iFM) Kit with 25ft sensor lead wires 59755002 15ft harness for power, fan, defrost heater 22699903 25ft harness for power, fan, defrost heater 22699902 40ft harness for power, fan, defrost heater 22699901...
  • Page 49 Replacement Parts List Table 4. intelliGen Retrofit Kits for Legacy Beacon II and QRC Controls (cont.) Defrost Voltage/ Color Retrofit Kit Model Family Model Size Description Type Phase Finish Part # 24" Fan INTELLIGEN RETROFIT, LUC, AD, 230/460V, 1PH, SMALL 89730401 230-460/1 30"...

  • Page 50: Replacing Carel Exv's

    Replacing Carel EXV's Preparation – POWER OFF To make the EXV is ready for removal, you will need to dis- connect the wiring harness from the top of the valve. Loosen the mounting screw holding the harness to the top of the valve and pull the plug straight up from the EXV to remove.

  • Page 51: Replacing Irc Board

    Replacing iRC Board Preparation – POWER OFF The iRC board has several different types of wiring connections and uses color coded terminals to bet- ter identify which terminals are inputs and which ones are output. There are also terminal identification labels stuck around the board to assist in reconnecting back to the correct locations.

  • Page 52: Replacing Irc User Interface

    Replacing iRC User Interface Preparation – POWER OFF To make the iRC UI ready for removal, you will need to disconnect the ribbon harness which also attaches to the iRC board. This special, locking ribbon connector is part of the iRC UI and is accessible from the back of the UI.

  • Page 53: Diagnostics & Troubleshooting Guide

    Diagnostics & Troubleshooting intelliGen Refrigeration Controller Troubleshooting Guide PROBLEM STEP ACTION ITEM IF NOT OK Check primary power supply 1. Check fuses and circuit breakers Check voltage to transformer 2. Check field wiring for breaks Check transformer secondary voltage 3. Replace transformer as needed Display is not lit.
  • Page 54 Diagnostics & Troubleshooting intelliGen Refrigeration Controller Troubleshooting Guide (continued) PROBLEM STEP ACTION ITEM IF NOT OK Check wiring connection to the board Check field wiring connection to the board Low Pressure Safety (LPS) Tripped: Low Pressure Safety (LPS) Tripped: • Change setpoint to match refrigerant •...
  • Page 55 Diagnostics & Troubleshooting intelliGen Refrigeration Controller Troubleshooting Guide (continued) PROBLEM STEP ACTION ITEM IF NOT OK Check 24 Volt Terminals for minimum 1. Check Primary Power Supply ER14: Power Supply Low 22 Volt and maximum of 30 Volt ER15: Power Supply High 2.
  • Page 56 Diagnostics & Troubleshooting intelliGen Refrigeration Controller Troubleshooting Guide (continued) PROBLEM STEP ACTION ITEM IF NOT OK Check for proper polarity at terminals for + 1. Check wires for damage and - ER25: System Cxn Lost Check all shield drain pigtails Check all shield drain pigtails Check for shield drain to ground screw 3.
  • Page 57 Diagnostics & Troubleshooting intelliGen Refrigeration Controller Troubleshooting Guide (continued) PROBLEM Step ACTION ITEM IF OK IF NOT OK Check system operation: Is it running? 1. Check power to condensing unit Check position of Service Mode switches Check compressor overloads and contactor Check system charge 2.

  • Page 58: Special Tips

    Special Tips Putting the System into Service Mode Turning the System On To put the system into the SERVICE mode, you must If the system has power and there is a call for cooling, the open the BOX SYS SETTINGS menu. It is the first item system should be on.
  • Page 59 NOTES:...
  • Page 60 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. ©2025 Heatcraft Refrigeration Products LLC The name behind the brands you trust. ™ CLIMATE...

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