Powers IntelliStation Installation guide

Brand: Powers

Model: IntelliStation

Type: Installation guide

This manual is also suitable for

Mechanical Sensor

IS-P-IntelliStation-Mech-Sensor

Installation Instructions

IntelliStation

Sensor Replacement

Temperature and Pressure Sensors

WARNING

Read this Manual BEFORE using this equipment.

Failure to read and follow all safety and use information

can result in death, serious personal injury, property

damage, or damage to the equipment.

Keep this Manual for future reference.

Product Description

The IntelliStation

is electronic water mixing system providing

user-directed control and monitoring of water distribution sys-

tems. IntelliStation

includes an electronically actuated valve that

mixes hot water with cold water, temperature sensors (plus a

quick response temperature sensor), pressure sensors, check

valves, and a recirculation pump to maintain the recirculation

loop temperature (reducing wait time for tempered water to

reach point-of-use fixtures, saving water and energy).

Hot

Water

Inlet

Cold

Water

Inlet

Mixed Water

Outlet

Typical

IntelliStation

T3P4 P3

FT1

Control Unit

Mixed Outlet

Temp & Pressure

Sensors

Hot Temp

& Pressure

Sensors

Electronically

Actuated Valve

Recirc Temp &

Pressure Sensors

Cold Temp &

Pressure Sensors

Recirculation

Pump

Return

Boiler

DESCRIPTION ORDER # WT. (LBS)

150psi Pressure Sensor (P1–P4) 81019288

.25

200psi Pressure Sensor (P1–P4) 88005572

High Speed Temperature Sensor (FT1) 81019289

Temperature Sensor (T1–T4) 81019061

NOTICE

• Temperature sensor wires are non-polarized and can be con-

nected to either terminal for a given sensor. Pressure and flow

sensors are terminal specific and need to be wired according

to the illustration.

• Only change one sensor at a time to reduce the potential of

connecting the wrong sensor to the wrong terminal.

• Water quality can cause scale to build up on sensor housing.

Sensors may malfunction due to this scale and may only need

to be cleaned and not replaced.

• It is good practice to use small stickers to “flag” each sensor

lead to better identify wires.

CAUTION

There are two types of pressure sensors used on IntelliStations, a

150psi and a 200psi sensor. Do not change sensor types. Doing

so will result in errors and improper operation.

Contact Tech Support to determine which sensor is installed on

your particular unit.

Sensor Care and Replacement

The following guidelines should be followed whenever servicing

any, or all, sensors on the Watts IntelliStation panel.

1. Disconnect the power supply from the IntelliStation panel.

2. Disconnect power to the circulator, if present. Circulators are

optional and may be powered through the IntelliStation or

they may be independently powered.

3. Close ball valves 1-5.

4. If replacing sensor, identify connection points for sensor

being replaced on main circuit board (see illustration).

5. Remove sensor from IntelliStation and disconnect from

circuit board.

6. Connect new sensor to circuit board and reconnect on

panel. Teflon tape should be applied to thread to ensure a

water-tight seal.

7. Repeat with each sensor needing to be replaced.

8. Open ball valves 1, 2, and 5 and let the system stabilize for

30 seconds.

9. Open ball valves 3 and 4.

10. Check sensors and verify no leaks are detected. If leaks are

detected repeat steps 3, 5–9.

11. Reconnect power to the circulator.

12. Reconnect power to the IntelliStation and turn on.

13. Verify no error codes are presented on the IntelliStation

monitor. Refer to the main IntelliStation Installation and

Operations Manual for error codes.

When the IntelliStation resumes operation there will be air in the

system. This will naturally diffuse out over time.

DANGER

Electricity, electrocution and shock hazards.

Mixed Outlet

Pressure Sensor (P1)

Recirc Pressure

Sensor (P2)

Cold Pressure

Sensor (P3)

Hot Pressure

Sensor (P4)

Optional Modbus

BAS Connection

1 2 4

R CCom

0-10

Act FB

Mtr

7 8 9 11 12 1310

FT1 Cs F2 +5V

Not Used

Gnd

1514

20 V F1

(dc)Sup

Ret V

4-20

BACnet

27 28 29 30 31 32 33 34

35 36 37 38

CsCs CsT1+5V+5V+5V +5V P4P3

T2 T3

P1 P2

2523 2422

Com Com Com Com

39 40

18 19

Gnd

RS-485

16 17

Alert

Relay

Recirculation

Pump

115 V (ac)

Power Supply

43 44 45 46

Power

Pmp

Recirc Return

Flow Sensor (F2)

Mixed Outlet

Flow Sensor (F1)

Mixed Outlet Temperature

Sensor (T1)

Mixed Outlet Fast

Temperature Sensor

Recirc Return Temperature

Sensor (T2)

Cold Supply Temperature

Sensor (T3)

Hot Supply Temperature

Sensor (T4)

Actuator

Motor

Optional BACnet

Connection

Alert Relay

RJ45

F1 Gnd +5 V

Sup V

USA: T: (800) 669-5430 • F: (847) 229-0526 • PowersControls.com

Canada: T: (888) 208-8927 • F: (888) 479-2887 • PowersControls.ca

Latin America: T: ((52) 55-4122-0138 • PowersControls.com

The Seller warrants that the equipment manufactured by it and covered by this order or contract is free from defects in material and workmanship and, without charge,

equipment found to be defective in material or workmanship will be repaired, or at Seller’s option replaced F.O.B. original point of shipment, if written notice of failure is

received by Seller within one (1) year after date of shipment (unless specifically noted elsewhere), provided said equipment has been properly installed, operated in accor-

dance with the Seller’s instructions, and provided such defects are not due to abuse or decomposition by chemical or galvanic action. THIS EXPRESS WARRANTY IS IN

LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, GUARANTEES, OR REPRESENTATIONS, EXPRESS OF IMPLIED. THERE ARE NO IMPLIED WARRANTIES OF

MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. The Seller assumes no responsibility for repairs made on the Seller’s equipment unless done by the

Seller’s authorized personnel, or by written authority from the Seller. The Seller makes no guarantee with respect to material not manufactured by it.