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What is IntelliCon®?
Does IntelliCon® really work, or is it just a “black box”?
How does IntelliCon work?
Why can’t my heating or cooling system perform this optimization without the IntelliCon?
Does the IntelliCon change the efficiency or operating characteristics of a burner or compressor?
If the burner or compressor is held off from starting its cycle longer, why doesn’t it run longer for the same amount of time?
If the burner or compressor is held off, why doesn’t the space temperature change?
I use a programmable, setback thermostat or a multi-zone thermostat. Will IntelliCon make any difference?
Q: What is IntelliCon?
A: IntelliCon is a line of energy-saving products for commercial and residential heating systems, central air conditioning systems and commercial refrigeration.
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Q: Does IntelliCon really work, or is it just a “black box?”
A: Intellidyne® products are proprietary microprocessor-based technology protected by three U.S. patents, with multiple patents pending around the world. See our Patents page for additional details.
Furthermore, Intellidyne products all have a money-back guarantee if the product fails to save at least 10% on your energy consumption.
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Q: How does IntelliCon work?
A: Our patented technology reduces energy consumption by optimizing system performance through real-time ‘load-demand’ analysis and control. In general, all IntelliCon products monitor the performance of the heating or cooling system and dynamically calculate the optimal performance for burner or compressor cycles. As the system load changes, IntelliCon automatically recalculates the optimal performance characteristics on the fly, ensuring that the system is always saving fuel and energy dollars. In real time, our products delay the start of a cycle so that the comfort of the space is maintained and the heating or cooling system is fully utilized. This cycle modification results in a more efficient use of the heating or cooling system, with subsequent reductions of energy consumption, wear and tear on the equipment, maintenance requirements and pollution.
A working description for each class of products is found below.
Also check out Learn More About the Products for more information.
- Hot Water and Steam Heating Systems
- IntelliCon analyzes the system’s load, or demand for heat, by monitoring the out-flow water temperature. The absolute temperature value of this water and the rate that the temperature is changing, are indicative of the load placed on the heating system. In addition, IntelliCon measures and records how many times the burner is turned on and off and the duration of those burner cycles. IntelliCon analyzes how fast heat is being lost in the system and, in turn, in the space. Using this information, IntelliCon calculates the optimum running cycle for maintaining the desired heating level. IntelliCon then intercedes and changes the way the burner is cycled by delaying the start of the burner cycle. As a result, less fuel is consumed in delivering the same amount of heating.
Forced Air Heating Systems- On a call for heat, the burner ignites, and the temperature in the heat exchanger section of the furnace begins to rise. Depending on the model and age of the furnace, the blower, or supply fan, will start when the heat exchanger has either reached a preset temperature, or when a timer signals. The supply fan begins moving air through your house, returning the cooler air back to the furnace for heating.
The IntelliCon monitors the temperature rise using its own sensor, which is mounted above the heat exchanger and in the airflow path. The sensor tracks the temperature rise throughout the burner cycle. As the heat exchanger warms up, the temperature rise begins to “flatten” or level out. This leveling out indicates that the output air temperature is beginning to stabilize as it is rising more slowly than at the beginning of the heating cycle.
The IntelliCon looks for this temperature stabilization. When the temperature remains constant for three minutes with little variation plus or minus 2 degrees, it will shut the burner off and enter the "Economy" mode. When in “Economy” mode, the IntelliCon prevents burner ignition, even if the thermostat continues to call for heat. Once the temperature at the IntelliCon sensor has dropped to the calculated optimal temperature, the burner is again allowed to fire. This firing cycle repeats until the thermostat no longer calls for heat.
As a result, the heated space receives a more even and comfortable heat. The temperature in the space “spikes" up and down less often and less drastically. Fuel bills are reduced accordingly, as the burner does not run as long to warm the space up to the desired temperature. Furthermore, the space temperature no longer "overshoots" the thermostat setting as the blower cools down an overly hot heat exchanger, even after the thermostat has shut the burner off.
The intelligent interaction between the IntelliCon, the thermostat and the burner ensures that the overall heating system provides a more even and comfortable level of heating while using less fuel. The IntelliCon ensures that the furnace delivers the appropriate amount of heated air necessary to heat the space at the desired temperature without jarring temperatures changes that are both perceptible and uncomfortable. At the same time, reducing the overall burner runtime measurably reduces fuel consumed while generating significant savings on your fuel bill.
Optionally, the return-air can be monitored as well for additional energy savings.
Central Air Conditioning Systems- For residential and commercial AC systems, IntelliCon analyzes the load, or demand, by monitoring how often and how long the thermostat is turning the compressor on and off, or cycling the compressor. The on-time to off-time ratios, and how these ratios are changing, indicate the load. IntelliCon intercedes and changes the way that the compressor is cycled by delaying the compressor start time. As a result, less electricity is consumed in delivering the same amount of cooling.
Commercial Refrigeration Systems- For commercial refrigeration systems, IntelliCon analyzes the load, or demand, by monitoring how often and how long the thermostat is turning the compressor on and off, or cycling the compressor. The on-time to off-time ratios, and how these ratios are changing, indicate the load. IntelliCon intercedes and changes the way that the compressor is cycled by delaying the compressor start time. As a result, less electricity is consumed in delivering the same amount of cooling.
Back to Top Q: Why can’t my heating or cooling system perform this optimization without the IntelliCon?
A: If a heating or cooling system is to perform properly (that is, keep a space properly heated, cooled or refrigerated on the hottest or coldest days), those systems must be sized according to the highest or lowest ambient temperatures they are to encounter. These worst-case hottest or coldest days (Design Days) occur only a small fraction of the time. Usually, though, the system is relatively over-sized for the demand, which causes the system to run, or cycle, less optimally.
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Q: Does the IntelliCon change the efficiency or operating characteristics of a burner or compressor?
A: No.
The IntelliCon product line does not increase a burner’s or compressor’s efficiency. We improve overall “System” efficiency by dynamically changing the way that the burner or compressor is reacting to the needs of the load placed upon it.
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Q: If the burner or compressor is held off from starting its cycle longer, why doesn’t it run longer for the same amount of time?
A: The very nature of a heating or cooling system requires it to either generate heat or extract heat faster than the load (space) loses or gains heat. (If this were not the case, the heating or cooling system would not be able to keep up with the demand and maintain the temperature, and it would run continuously.) As a consequence, system run-time is increased by only a fraction of the time that it was held off, resulting in a net reduction of energy consumed with no change in space temperature.
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Q: If the burner or compressor is held off, why doesn’t the space temperature change?
A: The answer depends upon the type of system.
- Hot Water and Steam Heating Systems
- There is substantial energy stored in the heating medium (water / steam) that can be extracted and used during the hold-off period without any substantial loss of output. This heat extraction is possible since the boiler can generate heat faster than it can be extracted. It also generates more heat than what can be extracted. Those two facts taken together explain why the space temperature doesn’t change while the burner cycling is optimized.
Forced Air Heating Systems- The rate and quantity of heat that a forced air heating system can add during a given period of time is greater than the amount of heat that can be lost by the load (space) for the same period of time. More simply, the system can heat the space faster than the space itself can cool off. In response, the burner must be cycled in order to maintain the desired temperature, otherwise the space would be over-heated. Air is used to inject heat into the space. Air has a very low mass and thus a short time-constant (the change in temperature per unit of time). Comparatively, items in the heated space—for example, people, walls, furniture and so forth—have considerably more mass and, thus, a longer time-constant. These higher mass items have a much greater thermal inertia. Thermal inertia (time-constant) indicates how fast or slow an object can be intrinsically heated or cooled over time. Higher mass items generally take longer to heat up or cool off than air. Since the burner is held off for only a small percentage of time, relative to the time-constants of the higher mass items, temperature fluctuations are virtually non-existent, and the temperature of the space is maintained while using less energy.
Central Air Conditioning Systems- The rate and quantity of heat that a central air conditioning system can remove during a given period of time is greater than the amount of heat that can be gained by the load (space) for the same period of time. More simply, the system can cool the space faster than the space itself can warm up. In response, the compressor must be cycled in order to maintain the desired temperature, otherwise the space would be over-cooled. Air is used to extract heat from the space. Air has a very low mass, and thus a short time-constant (the change in temperature per unit of time). Comparatively, items in the cooled space—for example, people, walls, furniture and so forth—have considerably more mass, and, thus a longer time-constant. These higher mass items have a much greater thermal inertia. Thermal inertia (time-constant) indicates how fast or slow an object can be intrinsically heated or cooled over time. Higher mass items generally take longer to heat up or cool off than air. Since the compressor is held off for only a small percentage of time, relative to the time-constants of the higher mass items, temperature fluctuations are virtually, non-existent and the temperature of the space is maintained while using less energy.
Commercial Refrigeration Systems- The rate and quantity of heat that a commercial refrigeration system can remove during a given period of time is greater than the amount of heat that can be gained by the load (space) for the same period of time. More simply, the system can cool the space faster than the space itself can warm up. In response, the compressor must be cycled in order to maintain the desired temperature, otherwise the space would be over-cooled. Air is used to extract heat from the space. Air has a very low mass and thus a short time-constant (the change in temperature per unit of time). Comparatively, items in the cooled space—for example, people, walls, furniture and so forth—have considerably more mass and, thus, a longer time-constant. These higher mass items have a much greater thermal inertia. Thermal inertia (time-constant) indicates how fast or slow an object can be intrinsically heated or cooled over time. Higher mass items generally take longer to heat up or cool off than air. Since the compressor is held off for only a small percentage of time, relative to the time-constants of the higher mass items, temperature fluctuations are virtually non-existent, and the temperature of the space is maintained while using less energy.
Back to Top Q: I use a programmable, setback thermostat or a multi-zone thermostat. Will IntelliCon make any difference?
A: These more advanced thermostat controls provide more fine-grained control of the temperature limits that trigger a call for heating or cooling by changing the trigger limits for a particular room (zone) or at a particular time (setback). Other than making the call for heating or cooling, these controls do not monitor or optimize the operation of the burner or compressor. As a consequence, the burner or compressor is still subject to the frequent and inefficient on/off cycling that is inherent in the design of the system.
Implementing an IntelliCon Economizer with a setback thermostat or a multi-zone control will still provide a minimum 10% reduction in energy consumed beyond what these controls might be providing already. These savings are derived from the dynamic, real-time burner or compressor cycle optimization that only the IntelliCon Economizer provides.
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