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Installation Instructions - Watts Water Technologies

1. DHWHow Mixed Outlet Flow Rate 9 RecrcHow Recirculation Return Flow Rate 12A Energy Used Totalized Energy Consumed through the Product R Dto3 4 10534 ajai jEmorCode Numericalerror RT f 00030 x Analog Value Objects Object Data Read Descipti R Val Mme Write ume epee lau O AV DHW Target Mixed outlet temeprature target 50 to 180 ERROR ERROR ERROR ERROR ERROR BACnet Binary Parameters m This control does not have any binary input parameters Binary Output Parameters Object sm een nwt sane os nre 6 Pump Relay Recirculation pump Status 0 1 on other Eror Communiationtror so R n a o no 1 yes BACnet Troubleshooting m If there is no or intermittent communication check the following Checkthe ethernet cable Cable length must not exceed 150 ft 45 7 m for CAT 5E or 300 ft 91 4 m for CAT 6 e fthe cable was manually made check continuity across each of the wires 47 tekmar IntelliStation BAS Integration Manual Modbus Specifications m odbus over RS485 S485 Two Wire plus Signal Ground 400 9600 19200 57 6k 115k default 19200 bps 8 AWG Shielded Twisted Pair STP Transmission Mode TU or ACSII default RTU J lt 177 m 580 ft lt 353 m 1 158 ft lt 1 000 m 3 280 ft lt 1 000 m 3 280 ft Maximum Cabl
2. PRGM Recirc Pump OFF 3 If the Hot Supply Temp is BELOW the Mixed Outlet Setpoint a Ensure flow is above the minimum rated flow by opening the hot water valve on two to four fixtures being supplied with tempered water from the panel Troubleshooting b Ensure that the hot water inlet isolation valve is in the fully Open ON position as shown below Closed OFF Open ON c Check the hot water source set point temperature and ensure that the hot supply line has no obstructions or closed valves restricting flow to the IntelliStation 4 Ifthe Hot Supply Temp is ABOVE the Mixed Outlet Setpoint there are no obstructions preventing hot water from reaching the panel and there is sufficient flow through the panel reset the control by pressing the icon to access the Programming menu Unlock the control see Unlock the System of this manual for more detail and then select the to navigate to the Toolbox menu shown below Load Defaults No Temperature Units E Flow Units gpm Energy Units MBtu Pressure Units psi 100 Do jO own eon within the Toolbox menu use the Down icon to highlight Reset as shown above then press efter This will access the Reset menu shown below pY Troubleshooting Toolbox Press the and then the control will reset and begin a start up sequence 5 Reset the control by opening and closing the circuit brea
3. Selecting directing and controlling a safe and properly designed thermal eradication protocol is the sole responsibility of the people who own manage or control the water distribution system It is their responsibility to protect water distribution end users facility employees or contractors and bystanders from scalding burning thermal shock or other hazards from possible exposure to water or any parts of the water distribution system during Sanitization and cool down period until system water returns to a safe and proper outlet water temperature set point A DANGER The Sanitization function produces high tempera ture water at all point of use fixtures faucets sinks tubs showers etc Only qualified and authorized personnel who fully understand the function s operation output and risks should use the Sanitization function and only as part of and in compliance with a thermal eradication pro tocol safely and properly designed by the owner or manager of the water distribution system The owner or manager of the water distribution system has sole responsibility to protect end users facility employees or contractors personnel performing the Sanitization and bystanders from scalding burning thermal shock or other hazards from possible exposure to water or any parts of the water distribution system during Sanitization and cool down period until system water returns to a safe and proper outlet water temperature set point
4. System Mixed Out Setpoint 140 F Mixed Out Maximum 180 F Valve Min 0 5 V Valve Max 9 5 V Mix Percent 5V 50 96 Manual Mixing Mode OFF Pump Operation Auto Back Up Down Enter The System Set up menu option are as follow System Setup Used when a fixed valve position is desired as when conducting the Self Manual Mixing Mode Balancing routine WARNING Turning this setting to On will create a scald risk See manual for more details Pump setting AUTO is temperature and pressure based pump control ON pump Pump Operation 5 D ON OFF pump is always OFF Head If pressure across the pump is If pressure across the pump is greater than inputed value pump will remain OFF inputed value pump will remain OFF Pump Min On Off Time The minimum time the pump remains on or off Return Target Designated temperature of return line water from facility Designated temperature delta to turn recirculation pump should return line Return Differential temperature fall below this value 29 The Sanitization function produces high water temperatures and is intended ONLY for use as part of a user directed controlled and supervised thermal eradication protocol that has been safely and properly designed to help limit water borne bacteria within the tempered water distribution system The instruc tions contained in this Manual for the Sanitization function are not intended to be a thermal eradication protocol
5. relay will operate Retum Temp Diff 1 F to 20 F 10 F The differential used to determine the pump on and pump off temperatures 0 to 1000 j Control Coefficient 0 to 100 11 Control Coefficient Note Valve Min Valve Max Kp Ki and Pump head setting only available when factory access code Is entered Note Manual Voltage only visible when Manual Mixing Mode is ON 12 Pump Operation Description of Controls and Functions Down Enter gt Network Menu Network Up MAC Address Back The Network Menu selections are generally described in the table below IP 0 0 0 0 IP Manual lt gt Auto Auto Always LT 0 0 0 0 Configuration Gateway 0000 0 0 0 0 Use mum entry mum thru 9 key in IP Address Buttons on screen are OK DEL TAB lt gt Use keypad entry 0 thru 9 key in Subnet IP Address Buttons on screen are OK ur TAB lt Use keypad entry 0 thru 9 key in Gateway IP Address Buttons on screen are OK DEL lt gt MAC Address 8 13 192 168 0 1 IP Configuration Manual 255 255 255 0 IP Configuration Manual 192 168 0 1 IP Configuration Manual IP Address 1 to 255 255 255 254 Subnet Mask 0 to 255 255 255 254 Gateway Address 1 to 255 255 255 254 MAC Address aa bb ee ff 11 22 Unique to Always each device Description of Controls and Functions BAS Menu The BAS Menu selections are generally described
6. Always read and follow the User Guide amp Instruction Manual 30 1 On the Programming Menu _ gt o w j 4 J ra 1 i 1 i i B v eme c1 Touch the SANITIZE icon which will direct you to the responsibility and liability acceptance page A DANGER The Programming Menu includes functions to control and or monitor water distribution system performance including hot water temperature in the system and at point of use fixtures faucets sinks tubs showers etc The owner or manager of the water distribution system is solely responsible for determining the safe and appropriate temperatures to protect people using contacting or exposed to water or any parts of the water distribution system from scalding burning thermal shock or other hazards and to control water borne bacteria in the system Only qualified and authorized personnel who fully understand each function s operation output and risks should use Programing Menu functions Always read and follow the User Guide amp Instruction Manual Are you authorized qualified and in full compliance with protocols safety practices and requirements and do you accept full legal liability and assume full responsibility for selecting Programming Menu functions including water temperatures that are safe and appropriate for the water distribution PD users and the facility 31 2 You must touch the
7. C above desired set point Listed without re circulation line amp pump temperatures and pressures for system users guests and facility User is responsible for determining safe and appropriate Relay Specification m gir serie 16A 250 VAC Alert relay 5A 250 VAC 5A 30 VDC Capacity m Flow Capacity at 50 50 mixed ratio Pressure Drop Across Valve Min System C 5psi 10psi 20psi 30psi 45psi 50psi Draw V 34kPa 69 kPa 138 kPa 207 kPa 310 kPa 345 kPa LFIS150 T agg 60901 85gpm 120gpm 147 gpm 180gpm 190 gpm 227 1 322lpm 454lpm 556lpm 681lpm 719lpm LFIS200 050 427 96 gpm 135 gpm 191 gpm 234gpm 286 gpm 302 gpm 363 511lpm 723lpm 886lpm 1083lpm 11431 With a properly sized pump Installation AAA Failure to follow all installation requirements risks possible death personal injury property damage and failure of the IntelliStation to perform as intended Installation of IntelliStation MUST be performed by qualified technicians including licensed electri cians and plumbers following all manufacturer s instructions complying with all local state federal and other governmental requirements and with all building and construction codes and standards Use ONLY with a potable water distribution system free of debris foreign materials corrosive
8. P2 sensor Faulty Cold Supply Ensure that P3 sensor wiring is correct Operate nominally Pressure P3 sensor Faulty Hot Supply Ensure that P4 sensor wiring is correct Operate nominally Pressure P4 sensor Faulty Mixed Outlet cc that Fl sensor wiring is correct Do not calculate energy Flow F1 sensor 12 Faulty Recirc Return Ensure that F2 sensor wiring is correct Do not calculate energy Flow F2 sensor 13 Temperature Automatically clears once T1 is within Operates Normally 5 F 2 8 C of the set point Increase Mixed Out Maximum within Max Temp Exceeded the System settings Control Resets Turn on a tap to cool down the system Manual Clear at the control after Ensure that supply water pressures System Failure P3 amp P4 are nominally equal Check valve and actuator for proper function Shuts Valve and does not operate any outputs NOTICE The alert relay is configured to close while an error is occurring Once the error is cleared the alert relay will open Scheduled Testing Inspection Testing Inspection Need for Periodic Inspection Maintenance This product must be tested periodically in compliance with local codes but at least once per year or more as service conditions warrant All products must be retested once maintenance has been performed Corrosive water conditions and or unauthorized adjustments or repair could render the product ineffective for the serv
9. Scheduled Testing Inspection 5 Using the 3 8 wrench install the support plate bolts see below until snug Ensure that the support plate bolts are sufficiently loose to allow for some very slight movement between the support plate and the actuator This play will allow the actuator to find the proper position when the armature clamping nut is tightened down Armeature Clamping Nut Support Plate Bolts 6 Tighten down the armature clamping nut using the 10mm socket and torque wrench to 50 in lbs 5 65 N m 7 Using the 3 8 socket elbow and torque wrench torque down the support plate nut to 50 in Ibs NOTICE Take caution not to overtighten and strip these nuts 74 Scheduled Testing Inspection 8 Run the control wires up to the control along the same path as when removed 9 Cut wires to an appropriate length and strip to allow for installation into the terminal blocks 10 Wire to terminal blocks as follows 1 0 10 Act Grey 2 Com N A 3 Mtr FB Pink 4 R Red 5 C Black NOTICE The Com terminal of the control is not wired amp orange actuator wire is not used by this control 11 Utilize cable ties to secure the wires and close the control module Once the box is closed re energize the unit 12 Resume normal operation and observe that the actuator and valve are now working properly Control Unit interior 1 Grey 2 N A 3 Pink 4 Red 5 Black 75 POWERS
10. 0 5 V Valve Max 9 5V Mix Percent 5V 50 96 Manual Mixing Mode OFF Pump Operation Auto Back Up Down Enter 2 Selecting and Setting Outlet Water Temperature Set point BEFORE setting mixed outlet water temperature or electing default tempera ture point of use mixing valves and or temperature limiting devices MUST be installed at all fixtures faucets sinks tubs showers etc 25 Using the 4 or 29 icons scroll through the System Menu and select Mixed Out Setpoint F System Mixed Out Setpoint 140 F Mixed Out Maximum 180 F Valve Min 0 5 V Valve Max 9 5V Mix Percent 5V 50 96 Manual Mixing Mode OFF Pump Operation Auto Back Up Down Enter 3 After selecting highlighting TS NNNM touch Enter and you will be directed to the Mixed Out Setpoint selection page system 4 Select and set the safe appropriate and desired outlet water temperature for your users application and facility by using the slider icon _ or by touching the right or left arrows until the selected temperature is displayed 26 The owner or manager of the water distribution system is solely responsible for determining the safe and appropriate temperatures to protect people using contacting or exposed to water or any parts of the water distribution system from scalding burning thermal shock or other hazards
11. 0 65535 Therms System Supply Sensor The accumulated energy usage gy or GJ present since last cleared System Return Sensor present GPM or m3 h Flow High 0 65535 GPM Optional F1 and F2 Flow The largest load flow measured Sensors present since last cleared Resolution in tenths Reset All ON lt gt OFF Aways Clear all monitored values to zero 15 Description of Controls and Functions Sanitize Function A DANGER The Sanitization function produces high tempera ture water at all point of use fixtures faucets sinks tubs showers etc Only qualified and authorized personnel who fully understand the function s operation output and risks should use the Sanitization function and only as part of and in compliance with a thermal eradication pro tocol safely and properly designed by the owner or manager of the water distribution system The owner or manager of the water distribution system has sole responsibility to protect end users facility employees or contractors personnel performing the Sanitization and bystanders from scalding burning thermal shock or other hazards from possible exposure to water or any parts of the water distribution system during Sanitization and cool down period until system water returns to a safe and proper outlet water temperature set point Always read and follow the User Guide amp Instruction Manual A See Sanitization section of this Manual for use instruct
12. 6 On the Toolbox menu use the Down icon to highlight Reset as shown above then press Enter This will access the Reset menu shown below Toolbox 7 Press the 3 and then and the control will reset and begin a start up sequence 8 Reset the control by opening and closing the circuit breaker switch and wait 60 seconds to resume normal operation A Always use proper precautions when accessing circuit breaker box 9 If problem persists after conducting the above outlined problem solving procedures contact Powers Technical Support at 800 669 5430 or info PowersControls com 62 Troubleshooting Problem If displays Instead measured value Solution 1 A sensor is not connected or functioning properly 2 Check the connection at the sensor and the connection within the control module A DANGER BEFORE attempting to open Control Module a certified and qualified elec trician MUST fully de energize and disconnect all electrical power from IntelliStation Perform required LOCK OUT TAG OUT procedures When done reconnection and reen ergizing of IntelliStation MUST be performed by certified and qualified electrician 3 Disconnect all power and fully de energize IntelliStation BEFORE opening the control module Open the Control Module and locate the non functioning sensor 4 Reset the control by pressing the PRISM icon to access the Programming menu Unlock the control see De
13. 93 50 bon E 56 00 1422 4 61 73 50 00 1568 0 1270 0 56 32 1430 5 189 6 270 5 209 6 124 8 63 0 209 0 299 8 206 4 Dimensions are shown x 1 2 Dimensions in parentheses are in mm IntelliStation Description and Specifications Specifications m Maximum Operating Pressure 125psi 861 Maximum Hot Water Temperature 2005 93 C Minimum Hot Water Supply 2 F 1 C Above Set Point Hot Water Inlet Temperature Range 120 1809 49 82 Cold Water Inlet Temperature Range 39 80 F 4 27 C 0 5 gpm 1 89 Ipm Outlet Water Temperature Adjustment Range 80 180 F 27 82 Listing Compliance ASSE1017 cUPC NSF CSA 24 UL873 BACnet Testing Laboratories BTL The wetted surface of this product contacted by consumable water contains less than 0 2596 of lead by weight With Equal Pressure Minimum flow when IntelliStation is installed at or near hot water source recirculating tempered water with a properly sized continuously operating recirculating pump ow limit cannot be less than the cold water temperature For best operation hot water should be at least 5 F 3
14. A Watts Water Technologies Company USA Tel 800 669 5430 Fax 847 229 0526 PowersControls com Canada Tel 905 332 4090 Fax 905 332 7068 e PowersControls ca Latin America 52 81 1001 8600 Fax 52 81 8000 7091 e PowersControls com IOM P SF IntelliStation 1520 EDP 2915182 2015 Powers
15. and to control water borne bacteria in the system 5 Once the desired temperature is selected press the icon to apply the setting You will be returned to the System Menu screen Commissioning m A You must confirm and test your outlet water temperature setting 1 Confirming proper setting and operation With your desired Outlet Water Temperature Set Point selected and set make sure the Mixed Outlet Temperature is within desired operating range Home Screen 27 If you are finished at this time the system will return to a locked state if not touched for 60 seconds Or touch the icon twice to return to the Programming menu then press LOCK 1 When the system is locked the Programming menu will now display the UNLOCK icon as shown below on left System Locked System UnLocked Programming 2 If you want to access other settings on the System Setup Menu touch the SETUP icon on the Programming Menu and follow the instructions under Accessing other settings on the System Setup Menu below 3 If you are done with programming and settings at this time touch the HOME icon on the Programming Menu and you will be returned to the Home Screen 28 Accessing other settings on the System Setup Menu 1 From the Programming Menu touch the icon to go to the System Setup Menu
16. chemi cals or substances and other adverse conditions IntelliStation is recommended for use as part of ASSE 1070 compliant water distribution system including mixing valves and or temperature limiting devices at all point of use fixtures faucets sinks tubs showers etc IntelliStation MUST be installed in a dry area not susceptible to freezing e Keep work area clean well lighted free of clutter and distractions and accessible only by autho rized personnel and workers ntelliStation Control Module and touchscreen display must be located in accessible and well lighted area for use servicing repair or replacement by authorized personnel IntelliStation Control Module is electrically powered ALWAYS take proper precautions to rec ognize evaluate and control electricity hazards during installation programming use and service maintenance NOTICE Installation of IntelliStation is performed by the owner using qualified and licensed trades such as plumbers and electricians following all local state federal and other governmental requirements and all building and construction codes and standards Step by step installation instructions depend upon the application and the configuration of the building s water distribution system All installations require thorough flushing of all piping BEFORE installation and testing for and eliminat ing all leaks before and after installation Check valves
17. death or serious injury Identifies hazards which if not avoided could result in death or serious injury Identifies hazards which if not avoided could result in minor or moderate injury NOTICE Identifies practices actions or failure to act which could result in property damage or damage to the equipment IntelliStation Description and Specifications The IntelliStation is electronic water mixing system providing user directed control and monitoring of water distribution systems IntelliStation includes an electronic Control Module featuring a color touchscreen digital display to select desired outlet water temperature 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 The IntelliStation monitors hot supply inlet temperature hot supply pressure mixed outlet temperature mixed outlet pressure mixed outlet flow rate optional return temperature and return pressure to help maintain the desired outlet water temperature IntelliStation also features a user programmable high temperature Sanitization mode to help limit water borne bacteria as part of a user directed and con trolled thermal eradication protocol The IntelliStation C
18. icon to proceed with the Sanitization function Touching the icon means you will be unable to utilize the Sanitization function and you will be returned to the Programming Menu page When you touch the you will be directed to the Sanitization menu screen Sanitization Temperature 160 F Time 60 min Back Up Down Enter 3 Select the Sanitization temperature first by highlighting the TEMPERATURE function on the Sanitization menu and then touching Enter 4 Using the slide bar or directional arrows select the desired outlet water temperature Sanitization 32 5 Next select the run time in minutes by first highlighting the TIME function on the Sanitization menu and touching Enter Sanitization Mode OFF T 155 F Back Up Down Enter gt select the desired Run Time 6 Using the 200 min BEFORE starting the Sanitization function make sure you are in full compliance with a safely and properly designed thermal eradication protocol protecting end users facility employees or contractors person nel performing the Sanitization and bystanders from scalding burning thermal shock or other hazards 33 7 engage start the Sanitization function select MODE on the Sanitization menu and touch Enter Sanitization Temperature 160 F Time 60 min Back Up Down Enter 8 Once in the MODE menu toggle to the ON radio button and then select
19. settings adjustment screen is shown below Building Automation OK To toggle from RTU to ASCII press on the next to the ASCII setting to change the icon to g indicating that this state is what is selected Press to save this setting and return to the Building Automation menu Note for additional information on configuring the Modbus settings see the Modbus Specifications of this document 45 tekmar IntelliStation BAS Integration Manual BACnet Protocol Implimentation Statement PICS Vendor Name tekmar Control systems Ltd Vendor ID 585 Product Name Intellistatiion Control Module Product Model Number 106901 Application Software Version J1245A Firmware Revision TBD BACnet Protocol Revision TBD Product Description The Intellistation is a mixing control designed to deliver tempered water to plumbing fixtures The con trol uses a Proportional Integral PI logic to accurately maintain a target temeprature by mixing a high temeprature water source with a low temeprature water souce This control also offers advanced fea tures including communication with a Building Automation System BAS IntelliStation provides user directed control and monitoring of water distribution systems It is the user s responsibility to select and main tain water temperatures and pressures that are safe and appropriate for the water system users guests and facility IntelliStation s Sanitization mo
20. to pro tect the wire from being damaged by the enclosure hole opening 97 tekmar IntelliStation BAS Integration Manual 4 If connecting the control to a BACnet IP supported BAS system simply run a CAT 5E or CAT 6 cable from the BACnet Network Switch and connect to the RJ45 Ethernet style jack on the board NOTICE Cable length not to exceed 150 ft 45 7m for CAT 5E or 300 ft 91 4 m for CAT 6 Check continuity across each wire 5 If connecting to a BACnet MSTP system run the A B Gnd terminals from the nearest BAS sys tem component and connect to terminals 21 20 and 22 Gnd of the IntelliStation Control Module 1069 A DANGER IntelliStation and BAS connections must be properly grounded DO NOT ground to the enclosure Ground Gnd terminal must be connected to terminal 22 marked Gnd 6 If connecting to a Modbus BAS system run the A B G terminals from the nearest the BAS system component and connect to terminals 20 21 and 22 DO NOT ground to the enclosure Ground G terminal must be connected to terminal 22 marked Gnd If connecting the Alert Relay simply wire positive and negative wires to terminals 18 and 19 If using the alert relay make sure not to exceed relay rating The alert relay is rated for 250 VAC 5A 6 30 VDC and not polarity sensitive 38 tekmar IntelliStation BAS Integration Manual 7 Once connected to the control clo
21. A DANGER BEFORE attempting to connect BAS a certified and qualified electrician MUST fully de energize and disconnect all electrical power from IntelliStation Perform required LOCK OUT TAG OUT procedures BAS connection MUST be performed by certified and qualified electrician 1 After completely de energizing and disconnecting all power from IntelliStation and performing required LOCK OUT TAG OUT carefully open the IntelliStation control module by releasing latches to reveal BACnet and Modbus hook up terminals 36 tekmar IntelliStation BAS Integration Manual the unit is de energized by measuring the AC voltage across the U and N terminals 46 and 45 respectively using the voltmeter Alternatively use a voltage detector to confirm that the unit is NOT energized T As an additional safety check once the box is open confirm that 2 With the control module open the BACnet Modbus and Alert Relay connections are visible on the bottom side of the main control board as shown below BACnet MSTP 2 lt gt en gt we 4 3 The control module has a plug installed in an unused hole through the enclosure to allow for easy installation of the BAS wires Remove this plug and run the BAS wires through this hole to the control NOTICE A grommet or wire protector similar to those used on the other enclosure holes should be used
22. Integration Manual Error Codes m Code jDesripion 4 Faulty Recirc Return T2 sensor 6 Faulty Hot Supply T4 Sensor 8 Faulty Recirc Return Pressure P2 sensor 9 Faulty Cold Supply Pressure sensor 50 Troubleshooting Problem Unstable control is observed at flow rates greater than the minimum rated flow Solution Balancing Routine 1 The Balancing Routine is designed to give the software additional information regarding the normal operating balance of the system to eliminate the need for a balancing valve 2 To conduct the Balancing Routine it is necessary to generate a load larger than the minimum rated flow rate using the following procedure To avoid scalding burning thermal shock or other hazards DO NOT use or allow anyone to use the water at any point of use fixture faucets sinks tubs showers etc in the facility s water distribution system during Balancing Routine The Balancing Routine can cause higher tem perature water in the system and delivered to point of use fixtures faucets sinks showers etc Only qualified and authorized personnel who fully understand the Balancing Routine s operation output and risks should perform this action Personnel performing Balancing Routine and the owner or manager of the water distribution sys tem MUST take appropriate safeguards to pro tect people from using contacting or exposure to water or any parts of the water distribu
23. OK Sanitization 34 The Sanitization Mode is now fully functional Note The HOME screen will indicate you are Sanitizing the water delivery system and indicate Mixed Outlet Temperature PRGM Recirc Pump STOP 9 After Sanitization Mode has completed user selected run time has elapsed the IntelliStation will go into a Cool Down Mode to return to the Mixed Outlet temperature prior to sanitizing PRGM Recirc Pump OFF 9b tekmar IntelliStation BAS Integration Manual Configuring the Control for BAS communication m 1 Configure the control to communicate using the User Interface BAS Menu information within this manual and or the BAS Integration Manual introduction The Intellistation is equipped with a 1069 Control Module designed and programed by tekmar Control Systems Ltd This control can communicate with a Building Automation System BAS using BACnet IP BACnet MSTP or Modbus This manual provides information about the measurements control parameters and error messaging which can be accessed by building automation and or management systems that use BACnet IP BACnet MSTP or Modbus communication The 1069 Control Module can be configured to provide remote monitoring and remote temperature set point control from the con nected BAS See IntelliStation User Guide amp Instruction Manual for additional information BAS Connection Procedure m
24. TU Address RTU lt gt ASCII BAS Type MODBUS RTU or ASCII Modbus Parity type tekmar IntelliStation BAS Integration Manual Building Automation Building Automation Building Automation BACnet Device ID 0000000 BACnet Device ID 0000001 Modbus Address BACnet Port 47808 Modbus Data Type RTU Register Foreign Dev OFF Modbus Baud Rate 9600 Modbus Parity Even Back Up Down Enter Up Down Enter Back Up Down Enter Each of the settings can be adjusted by depressing the YUP and Down icons to highlight the setting of interest and depressing the Enter icon to adjust the setting BACnet Specific Settings The BACnet Device ID setting adjustment screen is shown below BACnet Device ID To adjust the ID depress the key 7 times and enter an ID appropriate for the remainder of the BAS system and press OK Similarly enter an appropriate BACnet Port To change Register Foreign Dev to ON scroll down to Register Foreign Dev using the Up and Down icons and select Enter The Register Foreign Dev setting adjustment screen is shown in the OFF state below mE Building Automation To toggle from OFF to ON press on the icon next to the ON setting to change to indicating that this state is what is selected Press IK to save this setting and return to the Building Automation menu shown below with Register Foreign Dev set to ON Note the additional setting availab
25. User Guide amp Instruction Manual IntelliStation Digital Water Mixing and Recirculation System 3 m Read this Manual BEFORE using this equipment Failure to read and follow all safety and use information can result yid in death serious personal injury property damage or damage to the equipment Visit PowersControls com with any questions Keep this Manual for future reference POWERS POWERS LIMITED WARRANTY LIMITATION OF REMEDY What is covered Powers warrants to the original purchaser only that the product it manufactured when used as intended and instructed is free from defects in materials or workmanship for five year warranty from date of shipment to the original purchaser What is not covered This Limited Warranty does not cover or is voided by a any product components or parts not manufactured by Powers b faulty or improper installation or unsuitable installation environment c failure to follow instructions or warnings d problems caused by unauthorized attachments modification repairs or parts e negligence or vandalism f problems due to foreign material adverse or improper water conditions chemicals contamination improper pH water treatment activities or products mineral deposits or decomposition by galvanic action 0 shipping defects or damage h normal wear and tear i any abuse misuse unintended use failure to maintain or inspect j any circumstances over whi
26. Y PERMANENT INOPERABILITY OF INTELLISTATION OR ANY COMPUTER NETWORK OR SYSTEM ANY UNAUTHORIZED USES USERS OR INTRUDERS OF THE INTELLISTATION OR ANY COMPUTER NETWORK OR SYSTEM ANY INTENTIONAL OR UNINTENTIONAL VIRUSES OR CORRUPTION OF ANY KIND OF THE INTELLISTATION OR ANY COMPUTER NETWORK OR SYSTEM OR ANY THIRD PARTY ACTION SUCH AS HACKING OR UNAUTHORIZED ACCESS OR USE OF THE INTELLISTATION OR ANY COMPUTER NETWORK OR SYSTEM Table of Contents Pm Safety Understanding Safety Information Radio Frequency Warnings amp Hazards Intellistation Description amp Specifications Description of Controls amp Functions oet up and Programming T tekmar Intellistation BAS Integration Manual Troubleshooting 0c eee scheduled Testing Inspection and Maintenance Attention Owners and Users Thank you for purchasing the Powers IntelliStation This equipment will provide safe and produc tive operation as long as it is installed set up used and serviced in accordance with the instruc tions in this Manual and is properly maintained Owners and users of this equipment have the responsibility to make certain that this equipment is used properly and safely To avoid the possibility of death serious personal injury property damage or damage to the equipment owners should not permit anyone to touch this equipment unless they are
27. agement Port Buttons on screen are OK DEL lt gt Modbus Address Modbus 1 to 247 BAS Type MODBUS Modbus Data Type RTU or ASCII Modbus Parity None lt gt Odd lt gt Even Modbus Parity type RTU lt gt ASCIl Description of Controls and Functions Monitor Function Touching the MONITOR icon on the Programming Menu will allow access to the Monitor Function System Monitor Mixed Outlet High 109 F Mixed Outlet Low 91 F Energy Used 0 MBtu Recirc Pump 0 hr Hot Inlet High 158 F Hot Inlet Low 140 F Load Flow High Back Up Down Enter The Monitor Function allows access to the following fields When is it oe Mixed Outlet 22 to 266 F Always The highest measured mixed outlet High temperature since last cleared Mixed Outlet 22 to 266 F Always The lowest measured mixed outlet Low temperature since last cleared 65535 hrs Always Accumulated run time hours of pump since last cleared Hot Inlet High 22 to 266 F Always The highest measured hot inlet temperature since last cleared 22 to 266 Always The lowest measured hot inlet tem perature since last cleared PSI or KPA Pressure High 0 65535 PSI Always The highest measured DHW outlet pressure since last cleared Resolution in tenths PSI or KPA Pressure Low 0 65535 PSI Always The lowest measured DHW outlet pressure since last cleared Optional F1 and F2 Flow Sensors present Ener
28. are recommended to prevent cross flow Description of Controls and Functions The following sections generally outline and describe the controls and functions of the IntelliStation Control Module you will experience when using the digital display See Set Up and Programming sec tion of this Manual for use instructions Always read the Manual and all product labels and follow all safety and other information If you are ever uncertain about a particular task or the proper method of operating this equipment ask your supervisor consult this Manual or visit PowersControls com Control Module and Digital Display The intelligence running the IntelliStation is contained within a Control Module The color and touch screen digital display allows the user to view temperatures pressures flow rates throughout the sys tem and to configure the controls The following sections describe and explain the user interface to assist in navigating and configuring the control After power up the Attention screen shown below will appear You have 60 seconds to begin sys tem navigation Start Up Screen Control requires 60 seconds after power up to begin mixing operation Time remaining 30 5 NOTICE The Control will begin mixing operation after 60 seconds The Attention message will appear again after 10 seconds of inactivity until the 60 seconds time has elapsed Description of Controls and Functions By
29. ch Powers has no control IN NO EVENT SHALL POWERS BE LIABLE TO BUYER OR THIRD PARTIES FOR ANY GENERAL SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO PROPERTY DAMAGE PERSONAL INJURIES LOST PROFITS LOSS OF SAVINGS OR REVENUE LOSS OF THE USE OF THE PRODUCT OR ANY ASSOCIATED PRODUCTS COST OF REPAIR COST OF ANY SUBSTITUTE PRODUCTS OR SERVICES DELAY DAMAGES LABOR CHARGES FINES PENALTIES ECONOMIC OR NON ECONOMIC LOSSES ARISING DIRECTLY OR INDIRECTLY FROM THE SALE PURCHASE OWNERSHIP INSTALLATION OR USE OF THE PRODUCT WHETHER BASED ON BREACH OF WARRANTY BREACH OF CONTRACT NEGLIGENCE STRICT LIABILITY OR ANY OTHER LEGAL THEORY What will Powers do THE SOLE AND EXCLUSIVE REMEDY UNDER THIS LIMITED WARRANTY OR ANY IMPLIED WARRANTIES is Within a reasonable period of time after receiving a timely and bona fide claim Powers will at its sole option a repair the product or b replace the product or component with a same or similar product replaced product is warranted for 90 days from the date of return shipment or for the balance of the original Limited Warranty period whichever is longer IN NO EVENT SHALL POWERS LIABILITY EXCEED AN AMOUNT EQUAL TO THE SALES PRICE OF THE PRODUCT To obtain warranty service Contact Powers at 1 800 669 5430 with description of the problem and proof of the date of original purchase Cost of shipping and insuring returned product must be paid by purchaser Powers is no
30. de is intended for use as part of a user directed controlled and supervised protocol that has been safely and properly designed It is recommended to install IntelliStation as part of a ASSE 1070 compli ant water distribution system including point of use mixings valves Always read and follow User Guide amp Instruction Manual and all prod uct warnings and labels and comply with all governmental and safety requirements BACnet Standardized Device Profile ANNEX L BACnet Application Specific Controller B ASC Supported BIBBS AnnexK SCS Note Device communication control password is tekmar Segmentation Capability Supported Able to transmit segmented messages INo Able to receive segmented messages Nos 04 Data Link Layer Supported Device Address Binding Supported BACnet IP Annex J Static Device Address Binding BACnet MSTP Network Security Options Supported ANSDG A 46 tekmar IntelliStation BAS Integration Manual BACnet Analog Parameters m Analog Input Objects Al Anolog Value Object AV Read R Read Write RAW Analog Input Objects ieee E DEM DHW Temp Mixed Outlet Temperature RP 5000180 1A DHW Recirc Temp Recirculation Return Temperature RTF 5000180 2A Hot Temp The hot inlet suply temeprature RF 5000180 DHWPresure The mixed outlet pressure 6jAI Hot Pressure Hot supply inlet pressure 8
31. e Length lt 1 000 m 3 280 ft PP NI ole eel jo jojo ct o mnmicicieiolo o c 5 5 e E 3 ct 5 D o o D o S v 1 000 m 3 280 ft 1 000 m 3 280 ft 1 000 m 3 280 ft 1 000 m 3 280 ft 1 000 m 3 280 ft Start Bit Bit Data Length Bits for RTU Mode Bits for ACSII Mode N eo o o e J 1 np Ko N Q O o c o eo o o c o J Bi Parity ven 1 Stop Bit default Even to 247 default 1 lt 44 0 5 X PEIS e WN un ct c o w ect M 48 tekmar IntelliStation BAS Integration Manual Modbus Parameters m Read R Read Write R W System Status Register Register Parameter Name Read Write Units Format Range 1 jpHWTagetMax jJ input 1016 j50to180 2 DHWTemp RTP input 1016 5002 ___ jDHWRedrcTemp Input 6 50to220 4 HotTemp gt input 1016 5002 SB ColdTemp jnpu 6 5002 6 DHW Pressure R Jpsix10 1016 010200 7 DHWhRecicPresure R _ jpsix10 npu
32. e stand m Actuator Replacement NOTICE To install a replacement actuator the positioning of both the actuator and valve needs to be confirmed prior to installation 71 Scheduled Testing Inspection and Maintenance 1 The actuator armature must be positioned in the un powered rest position Marked Correct in the picture below Actuator Correct Incorrect Incorrect lt 5 2 To adjust the armature position depress the actuator manual override button see below and turn the armature to the Correct position shown above Actuator Manual Override Button 3 The valve must be positioned such that it is fully opened to the branch cold supply The Correct and Incorrect positions are shown below These images are looking in the outlet port of the valve note the black plastic flow linearization insert NOTICE When positioned correctly the valve outlet plastic insert will be fully open to the cold inlet side of the valve 72 Scheduled Testing Inspection Correct 4 Once both the actuator and valve have been aligned correctly the actuator can be reinstalled onto the valve by sliding actuator over the valve stem until the actuator sits tight against the actuator sup port plate with the actuator positioned vertically as shown below NOTICE The valve outlet with plastic insert should be facing upwards Valve Actuator Correct 72
33. hecking the hose outlet for flow After generating a load allow 2 minutes for the system and sensors to reach steady temperatures 15 On the Home screen navigate the top field to the Hot Mix Ratio by pressing the arrow to the right of the field 25 Troubleshooting 16 Record the Hot Mix Ratio observed after the 2 minutes has elapsed Note Value should be relatively stable and unchanging 17 Turn off the load by closing the pump inlet hose connect valve NOTICE Make sure hose connection valve is fully closed and all water flow through valve is stopped before detaching hose 18 From the Home screen navigate to the System settings by pressing PRIM unlock the control functions BEFORE continuing You MUST read understand and accept risks of Programming menu 19 Touch the SETUP icon then the System icon Highlight Mix Percent 5V using the Up Down icons Mixed Out Setpoint Max 140 F Mixed Out Setpoint 140 F Mixed Out Maximum 150 F Manual Mixing Mode ON Manual Voltage 5 0 V Pump Operation Auto Pump Min On Off Time 1 min Up Down Enter 56 Troubleshooting 20 Press Enter and use the arrows gt and or scroll bar JS to change this value to the value you recorded in Step 716 above System 21 Press OK to return to the System settings menu Highlight Manual Mixing Mode using the Down icons and press Enter 22 Return Manual M
34. ice intended Regular checking and cleaning of the product s internal and external components helps assure maximum life and proper product function 67 Scheduled Testing Inspection and Maintenance Actuator and or Valve Removal NOTICE Valves and actuators are not field serviceable They must be removed and replaced Tools Required e 10mm and e sockets elbow and torque wrench Not required if replacing both valve and actuator 5 wrench Not required if replacing both valve and actuator 25mm Allen key Not required if replacing both valve and actuator e 1 3 3 2mm 2 slot screwdriver Not required for valve only replacement Wire Stripper and snips Not required for valve only replacement AC Voltmeter Not required for valve only replacement Five to ten 4 zap straps cable ties e 4 monkey wrenches gas grips e 3 adjustable wrenches shifting spanner Teflon Tape Not required for actuator only replacement m Actuator Removal Instructions A DANGER BEFORE attempting to open Control Module a certified and qualified elec trician MUST fully de energize and disconnect all electrical power from IntelliStation Perform required LOCK OUT TAG OUT procedures When done reconnection and reen ergizing of IntelliStation MUST be performed by certified and qualified electrician 68 Scheduled Testing Inspection 1 Once de energized and disco
35. ill appear and you will be prompted to enter the passcode 20 56 Back Clear Enter 4 Creating your own passcode To create your own passcode enter the factory default passcode 1017 and press the the lower right corner of the Unlock screen Enter a new 4 digit passcode and touch the Enter icon make sure to keep your new code in a secure place Re enter the new passcode and touch the Enter icon again to finalize the passcode change fF iconin NOTICE If you make a mistake when re entering your new passcode and it does not match your first entry the Enter icon will be deactivated If this happens press Clear and try entering the new passcode again NOTICE To reset the passcode to the factory setting on the Programming menu press and hold the SETUP icon for 10 seconds When the passcode is reset you will be automatically directed to the Unlock page Unlock the system m 1 To unlock the system on the Unlock screen enter your new passcode and touch the Enter icon NOTICE If you need to clear your entry and start again touch the Clear icon If you want to go back to Programming Menu touch the Back icon 2 If you did not set up your own passcode you can enter the factory default passcode 1017 2 When the passcode is entered you will be directed to the liability and responsibil
36. in the table below When Displayed Additional Info Building Automation Type None control runs in stand alone BAC IP control NONE is connected to a BAS Type BAC IP lt gt BAC Always BACnet IP system MSTP lt gt MODBUS BAC MSTP control is connected to a BACnet MS TP system MODBUS control is connected to a Modbus system BACnet BAS Type BAC IP or DEVICE ID 0 to 4194302 BAC MSTP BACnet device ID Use keypad entry thru 9 BACnet Port 1 to 65535 BAS Type BAC IP key in BACnet PORT BACnet Port Buttons on screen are OK DEL lt gt Is a BACnet Device that has an IP subnet Register i OFF lt gt ON BAS Type BAC IP address different from Foreign Dev ie those comprising the BACnet IP network BAS Type BACnet e nA BACnet Broadcast Register Foreign Dev Use keypad entry Management A speci BBMD TIME OFF 30 to 65535 OFF OFF Othru 9 neo Ume ex OCI that time by periodic key in BBMD TIME automatic renewal are OK DEL gt gt RTU Buttons on screen Feds BAS BACnet USe Keypad entry 0 mE thru 9 BACnet Foreign device BBMD IP Register Foreign Dev gt internet Protocol 0 to 255 255 255 255 127 127 127 127 OFF key in IP Address address A numerical label assigned to the Buttons on screen foreign device are OK DEL lt gt Use keypad entry BAS Type BACnet Othru 9 BBMD PORT 010 65535 47808 kevinBEMEPORT pace OFF Man
37. ion system users and the facility You will be returned to the Programming screen 22 4 When you touch the MEGEN icon you will access the Programming Menu which will appear as Programming Selecting and adjusting the mixed outlet water temperature m A DANGER The next steps involve selecting or adjusting the mixed outlet water temperature the hot water temperature in the water distribution system and delivered to point of use fixtures faucets sinks tubs showers etc The owner or manager of the water distribution system is solely respon sible for determining the safe and appropriate temperatures to protect people using contacting or exposed to water or any parts of the water distribution system from scalding burning ther mal shock or other hazards and to control water borne bacteria in the system Only qualified and authorized personnel who fully understand each function s operation output and risks should use Programming Menu functions Always read and follow the User Guide amp Instruction Manual 23 Touch the SETUP icon which will direct you to the Setup Menu which will appear as 24 Touch the System icon which will direct you to the System Menu which will appear as System Mixed Out Setpoint 140 F Mixed Out Maximum 180 F Valve Min
38. ions Description of Controls and Functions Touching the SANITIZE icon on the Programming Menu will allow access to the sanitization Function Sanitization Temperature 160 F Time 60 min Back Up Down Enter The Sanitization Function allows access to the following fields Mode ON lt gt OFF OFF After PIN correctly Turn sanitization on or off entered Tenes to 180 140 F After PIN correctly The sanitization M entered M Countdown starts Time 10 09 once DHW is to the Sanitization Timer hrs entered iig Sanitization Temperature 17 Description of Controls and Functions Toolbox Function Touching the 894 icon on the Programming Menu will allow access to the Toolbox Function Load Defaults Temperature Units Flow Units gpm Energy Units MBtu Pressure Units psi Backlight 100 Reset No Back Up Down Enter The Toolbox Function allows access to the following fields When Displayed Additional Info Firmware Always SVN XXX Load Defaults No Yes No Always to factory defaults GPM gt lt mih lt gt Optional F1 or Flow Units LPM GPM F2 Flow Sensors Units used for Flow Rate display present Units used for calculated Ener Energy Units MBtu kWh MBtu F2 Flow Sensors gy Usage display present Adjust the brightness of the LCD 0 0 Backlight 10 96 10096 Alwa
39. ity acceptance screen 4 DANGER The Programming Menu includes functions to control and or monitor water distribution system performance including hot water temperature in the system and at point of use fixtures faucets sinks tubs showers etc The owner or manager of the water distribution system is solely responsible for determining the safe and appropriate temperatures to protect people using contacting or exposed to water or any parts of the water distribution system from scalding burning thermal shock or other hazards and to control water borne bacteria in the system Only qualified and authorized personnel who fully understand each function s operation output and risks should use Programing Menu functions Always read and follow the User Guide amp Instruction Manual Are you authorized qualified and in full compliance with protocols safety practices and requirements and do you accept full legal liability and assume full responsibility for selecting Programming Menu functions including water temperatures that are safe and appropriate for the water distribution users and the facility 3 You must touch the icon to proceed to the Programming Menu and to use system functions Touching the icon means you will not be able to change system settings and you accept all default settings including the outlet water temperature set point of 120 F 49 C as safe and appropri ate for the water distribut
40. ixing Mode to Off state by touching the icon Press OK to return to the System settings menu Note The Manual Mixing Mode will now be OFF the Manual Voltage will not be shown and the Mix Percent Q 5V will be set to the value you recorded and set in this procedure default 50 shown below y 5 em Pa Mixed Out Setpoint Max 140 F Mixed Out Setpoint 140 F Mixed Out Maximum 150 F Mix Percent 5V 50 Pump Operation Auto Pump Min On Off Time 1 min Return Target 130 F 23 Press Back to return to the Programming menu Press Back again to return to the Setup menu Press and Back again to return to the Programming menu 24 Press HOME to navigate to the home screen Proceed to the Set up And Commissioning proce dure outlined in this Manual to ensure proper operation at these new settings 27 Troubleshooting Problem Outlet temperature is below set point temperature and or the low temperature alarm has been activated Solution 1 Depending on the heating plant plumbing and location it may take several minutes for the hot water to reach the panel Ensure that you have allowed enough time 5 minutes for the system to come up to temperature 2 On the Home screen check the Mixed Outlet Setpoint and the Hot Supply Temp using the icon to cycle through the fields The Hot Supply Temp needs to be above the set point or the panel will not be able to reach the set point
41. ker switch and wait 60 seconds to resume normal operation A Always use proper precautions when accessing circuit breaker box NOTICE problem persists after conducting the above outlined problem solving procedures contact Powers Technical Support at 800 669 5430 or info PowersControls com 60 Troubleshooting Problem Outlet temperature above set point Solution 1 Ensure flow is above the minimum rated flow by opening the hot water valve on two to four fixtures being supplied with tempered water from the panel 2 Ensure that the cold supply isolation valve is in the fully open position as shown below Closed OFF Open ON 2918098431 3 On the Home Screen check the Cold Supply Temp using the Bl icon see below to cycle through the various fields Ensure that it is lower than the set point temperature and that the cold supply line has no obstructions or closed valves restricting flow to the IntelliStation 4 Reset the control by opening and closing the circuit breaker switch and wait 60 seconds to resume normal operation A Always use proper precautions when accessing circuit breaker box 61 Troubleshooting 5 Unlock the control see Unlock the System of this Manual for more detail and then select the Foss to navigate to the Toolbox menu shown below Toolbox Load Defaults No Temperature Units F Flow Units gpm Energy Units MBtu Pressure Units psi 100
42. le with the Register Foreign Dev set to ON 43 tekmar IntelliStation BAS Integration Manual BAS Type BAC IP BACnet Device ID 0000001 BACnet Port 47808 BBMD Time BBMD IP Address gt BBMD Port 47808 The BBMD Time and BBMD Port are adjusted similarly to the BACnet Device ID The BBMD IP Address adjustment screen is shown below Use the Tab icon to move bewteen the four groups of three numbers use the gt move around in each group of 3 numbers and use the Del to delete the numbers entered in the field to allow entering a new number Note for additional information on configuring the BACnet settings see the BACnet Specifications of this document Modbus Specific Settings m The settings available pi BAS Type are shown below Fach of the settings can be adjusted by depressing the Up Down cEnter icon to adjust the setting Modbus Address Modbus Data Type RTU Modbus Baud Rate 9600 Modbus Parity The Modbus Address setting adjustement screen is shown below 44 tekmar IntelliStation BAS Integration Manual Building Automation OK lt gt To adjust the Modbus Adress either press anywhere on the slider bar 74 and or use the arrow keys amp and then select OK to save the setting and return to the Building Automation menu The ModBus Baud Rate and Modbus Parity are adjusted in a similar fashion The Modbus Data Type
43. nnected the display will become inactive and the control box can be opened As an additional safety check once the box is open confirm that the unit is de energized by measuring the AC voltage across the and N terminals 46 and 45 respectively using the voltmeter Alternatively use a voltage detector to confirm that the unit is NOT energized 2 Using the slot screwdriver loosen terminals 1 to 5 0 10 Act Com Mtr FB R C respectively in the upper left side of the control module Take note of the wire colors connected to each of the termi nals This connection should be as follows 1 Grey 2 N A 3 Pink 4 Red 5 Black Control Unit interior 1 Grey 2 N A 3 Pink 4 Red 5 Black 3 Locate the Actuator Cable Remove the Actuator Cable from the control box and stand supports If needed snip cable ties making sure not to damage any other wires when removing the cable ties 4 Also note the routing of the actuator cable for reinstallation 5 Remove the actuator from the valve as follows a Using the 3 8 wrench remove the two actuator support plate bolts see image p 73 b Using the 10mm wrench loosen the actuator armature clamping nut see image p 73 c Using the 3 8 wrench completely remove the support plate bolts d At this point the actuator should be free to slide off the valve stem away from the valve If not fur ther loosen the actuator armature clamping nut e Carefully remove the ac
44. not repeat the Unlock steps again 8 On the Programming Menu select the BEWA function icon to access the control settings 53 Troubleshooting 9 On the Setup function screen select the System menu System Mixed Out Setpoint 140 F Mixed Out Maximum 180 F Valve Min 0 5 V Valve Max 9 5 V Mix Percent 5V 50 Manual Mixing Mode OFF Pump Operation Auto Back Up Down Enter 10 Using the YP or Dewn icons scroll through the System menu and highlight Manual Mixing Mode Press Enter 11 Select RSM then press OK in the bottom left hand corner of the display This returns you to the System menu Troubleshooting 12 On the System menu System Mixed Out Setpoint 140 F Mixed Out Maximum 180 F Valve Min 0 5 V Valve Max 9 5 V Mix Percent 5V 50 96 Manual Mixing Mode OFF Pump Operation Auto Back Up Down Enter Use the YP or Down icons to scroll through the System menu and select and highlight Manual Voltage Press Enter Change the setting to 5 0 V using the arrows and or the scroll bar Once set to 5 0 V press 13 Pressing OK will direct you back to the System menu Press Back to navigate back to the Setup menu Press Back again to navigate to the Programming menu Press access the Home screen and view the available system temperatures 14 Generate a load by opening the pump inlet hose connect valve Visually confirm that the valve is open by c
45. onnected to a Modbus system BACnet Port Is a BACnet Device that has an IP subnet address different from those comprising the BACnet IP network BACnet Broadcast Management A specified time extend ing that time by periodic automatic renewal requests BACnet Foreign device internet Protocol address A numerical label assigned to the foreign device BACnet Broadcat Management Port BAS Menu Range When is it Displayed NONE lt gt BAC IP lt gt BAC MSTP lt gt MODBUS BAS Type Always BAS Type BAC IP or BAC MSTP BACnet BACnet Port 1 to 65535 OFF lt gt 0N OFF 30 to 65535 Use keypad entry 0 thru 9 key in BACnet PORT Buttons on screen OK DEL lt gt 47808 BAS Type BAC IP Register Foreign Dev 2 BBMD IP 127 127 127 127 BAS Type BAC IP Time to live BAS Type BACnet Seconde Use keypad entry 0 thru 9 key in BBMD TIME Buttons on screen are OK DEL lt gt Use keypad entry 0 thru 9 key in IP Address Buttons on screen are OK DEL lt gt Register Foreign Dev OFF BAS Type BACnet to 255 255 255 255 Register Foreign Dev Use keypad entry 0 thru 9 key in BBMD PORT Buttons on screen are OK DEL lt BAS Type BACnet Register Foreign Dev OFF BBMD PORT 0 to 65535 47808 Modbus Address 1 to 247 a BAS Type MODBUS Modbus Data Type 42 OFF OFF R
46. ontrol Module supports building automation systems BAS communication with BACnet IP BACnet MSTP and Modbus protocols allowing remote programming and data viewing Installation and adjustment of the IntelliStation are the responsibility of the owner and installer and must be done by qualified personnel in accordance with the manufacturer s instructions and complying with all governmental requirements building and construction codes and standards It is recommended to install IntelliStation as part of an ASSE compliant water distribution system including mixing valves and or temperature limiting devices at all point of use fixtures faucets sinks tubs showers etc that are approved to ASSE 1016 1069 1070 and 1071 The owner and user of the IntelliStation is responsible for selecting and installing the product in an appropriate water distribution system proper sizing main taining proper water quality condition and deciding what temperature is safe and appropriate for the water distribution users and facility IntelliStation Description and Specifications 4 91 248 il 5 12 The IntelliStation components are shown below Control Unit Temp amp Pressure Sensor d E Temp amp Pressure Sensor 8 L i Recirculation i Electronically Pump Actuated Valve 3 D Temp amp Pressure E Sensor D 0 Dimensions LFIS150 LFIS200 33 28 845 3 31 28 794 5 19
47. ouching the HOME icon takes the user back to the Home Screen Touching the UNLOCK icon takes the user to the Unlock function screen shown below Unlock Function Description of Controls and Functions To set and enter a passcode and unlock the system follow instructions in the Set Up and Programming section of this Manual NOTICE The Enter icon on the Unlock function screen is deactivated until the user enters the correct pass code The Baek icon will take you back to the Programming Menu The icon will show additional information if available After entering the correct passcode the Setup Monitor Sanitize and Toolbox functions can be accessed from the Programming Menu screen The following Sections generally outline and describe these functions Touching the SETUP icon on the Programming Menu will allow access to the Setup function Setup Function Back The Set up Function allows the user to access three menus System m Network BAS Description of Controls and Functions System Menu System Mixed Out Setpoint 140 F Mixed Out Maximum 180 F Valve Min 0 5 V Valve Max 9 5 V Mix Percent 5V 50 Manual Mixing Mode OFF Pump Operation Auto Back Up Down Enter The System Menu selections are generally described in the table below Default Additional Info SU MEd OM Limit to the remote temperature adjustment Mixed Out Se
48. over 18 years of age are adequately trained and supervised and have read and understand this Manual Owners should ensure that no unau thorized personnel come in contact with this equipment ment and contact an experienced service indi vidual immediately If the product labels or this Manual are misplaced damaged or illegible or if you require additional copies please visit PowersControls com Please remember that this Manual and the product labels do not replace the need to be alert to properly train and supervise users and to use common sense when using this equip ment If you are ever uncertain about a particular task or the proper method of operating this equipment ask your supervisor consult this Manual visit PowersControls com or contact your local sales representative READ THIS MANUAL carefully learn how to install set up use service and maintain this equip ment correctly and strictly fol low all safety information and instructions contained in this Manual and on the equipment as well as any requirements of local state and federal law Failure to do so could result in death serious personal injury property damage or damage to the equipment This Manual should be considered a perma nent part of the IntelliStation and be kept avail able for easy reference by any user If this equipment or any of its parts becomes damaged or needs repair stop using the equip Product Identification Please
49. record your product s identification and purchase information which will help in the event you have questions or need any service Date of purchase Seller name address Important Safety Information Reading amp Understanding the Manual Learn how to properly and safely use the equipment BEFORE installing set up using or servicing e Keep the Manual available for easy access and future reference e Replace missing damaged or illegible Manual and product labels e Replacement Manuals available at PowersControls com TO AVOID DEATH SERIOUS PERSONAL INJURY PROPERTY DAMAGE OR DAMAGE TO THE EQUIPMENT e Read the Manual and all product labels and follow all safety and other information Understanding Safety Information This pictorial alerts you to the need to read the manual 2 This pictorial alerts you to scalding burn and hot water hazards AN This pictorial alerts you to burn and hot surfaces hazards This pictorial alerts you to elec tricity electrocution and shock hazards This pictorial alerts you to the need to perform appropriate Lock Out Tag Out procedures This safety alert symbol is shown alone or used with a sig nal word DANGER WARNING or CAUTION a pictorial and or a safety message to identify hazards and alert you to the potential for death or serious personal injury A DANGER Identifies hazards which if not avoided will result in
50. rom within the Programming menu The System Monitor Screen is shown below Mixed Outlet High 109 F Mixed Outlet Low 91 F Energy Used 0 MBtu Recirc Pump 0 Hot Inlet High 158 F Hot Inlet Low 140 F Load Flow High gom UD Dowm Emer wo The How to Clear information presented below is also available from within the control user interface by pressing the key from within the System Monitor while viewing the Current Error For more information on navigating and using the user interface see the control module interface 65 Troubleshooting TA Control Behavior Code Description How to Clear D during Error Condition NVM Error Load defaults and or power cycle the Do not operate any outputs control Faulty Mixed Outlet ensure that the T1 wiring is correct Do not operate any outputs T1 sensor Faulty Mixed Outlet Ensure that the wiring is correct Do not operate any outputs FT1 sensor Do not calculate energy Faulty Recirc Return Ensure that the T2 wiring is correct Do not operate recirculation T2 sensor pump Do not calculate energy Faulty Cold Supply Ensure that T3 sensor wiring is correct Operate nominally T3 sensor Faulty Hot Supply Ensure that T4 sensor wiring is correct Operate nominally T4 sensor 7 Ensure that P1 sensor wiring is correct Operate nominally Pressure P1 sensor FOU Rec Ensure that P2 sensor wiring is correct Operate nominally Pressure
51. se the enclosure and reconnect the power BACnet and Modbus Settings in the Intellistation Control Module Menu When the unit powers up it displays the warning message shown below until 60 seconds has elapsed After 60 seconds the control will automatically redirect to the Home screen The settings menu can be accessed prior to the time elapsing by touching anywhere on the screen Control requires 60 seconds after power up to begin mixing operation Time remaining 60 5 From the home screen depress the PRGM icon to access the Programming menu From within the Programming menu shown below only the icons are active until the control is in the unlocked state Note After 60 seconds of inactivity the control automatically locks and returns to the home screen Programming Unlock Back Clear Enter 7 To unlock the control select the icon from within the Programming menu 39 tekmar IntelliStation BAS Integration Manual select 6168 to try again Note the Enter icon will only work if the correct code is entered Once unlocked the control automatically redirects to the Programming menu but this time the UNLOCK icon will appear as BENI icon indicating that the control is unlocked and the other icons SETUP MONITOR SANITIZE TOOLBOX will now be active Unlock the control by entering 1017 and selecting the Enter icon If the wrong code was entered Programming Select
52. t 1016 JOto200 B fHotPressure __ R jpsix10 1016 010200 9 jColdPresue R jpsix10 1016 010200 10 Valve Position Input 06 0101006 11 Pumpstatus _ U16 0508 1 0 02 pHWFow R jGPM 1016 JOto160 13 DHWRecrcFow R GPM 6 JOto40 14 jEnergyUsed Jtherms U16 01065535 15 fErrorCode JR Enum input 16 Error Code list System Parameter Register Read Write Units Type Format Range 1 pHw Target mw U16 50 to Target Max Product Information Read Write Units Type Format Range 1 Model Num 016 Product model 1069 2 jFimwareRevision R input 16 SVN revision Modbus Troubleshooting m If there is no communication check the following Check that the polarity on the Modbus and terminals is correct Check that the Modbus GND terminal is securely connected Checkthat the Baud Rate on both devices are the same If the communication is intermittent check the following Checkthat the communication cable is of twisted pair type Reliable communication depends on the cable length amp Baud Rate used Long cable length may require a lower Baud Rate 49 tekmar IntelliStation BAS
53. t responsible for any loss of damage to the product incurred during shipping Disclaimer of other warranties THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED ALL IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED POWERS COMPUTER SYSTEM NETWORK AND DATA DISCLAIMER IntelliStation receives stores and displays data concerning your water distribution system performs functions based upon owner user data Input and slections and can be remotely programmed and utlitized with specified and compatible building automation systems AS SUCH POWERS MAKES NO EXPRESS OF IMPLIED WARRANTY INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE REGARDING COMPATIBILITY WITH OTHER TECHNOLOGIES HARDWARE SOFTWARE NETWORK OR SYSTEMS THE ACCURACY OR COMPLETENESS OF ANY DATA THE SECURITY OF ANY COMPUTER NETWORK OR SYSTEM OR ANY RESULTS TO BE ACHIEVED FROM THE INTELLISTATION OR ANY COMPUTER NETWORK OR SYSTEM POWERS HAS NO RESPONSIBILITY OR LIABILITY ARISING FROM THE UNAUTHORIZED USE OF THE INTELLISTATION THE CONNECTION TO OR INTEGRATION WITH A USER S OR ANY OTHER COMPUTER NETWORK OR SYSTEM ANY HARDWARE OR SOFTWARE NOT SUPPLIED BY POWERS ANY DATA THAT IS INCORRECT CORRUPT OR CORRUPTED LOST STOLEN OR PIRATED ANY FAILURE TO SECURE THE INTELLISTATION OR THE USER S OR ANY OTHER COMPUTER NETWORK OR SYSTEM ANY CRASHING OR TEMPORAR
54. tailed User Interface this manual and then select the 888 to navigate to the Toolbox menu shown below Toolbox Load Defaults No Temperature Units T Flow Units gpm Energy Units MBtu Pressure Units psi GE 100 From within the Toolbox menu use the Down icon to highlight Reset as shown above then press Enter This will access the Reset menu shown below 63 Troubleshooting Toolbox Press the EZ and then OI and the control will reset and begin a start up sequence Note Alternatively the control can be reset by opening and closing the circuit breaker switch and wait ing 60 seconds to resume normal operation A Always use proper precautions when accessing circuit breaker box 5 Wait 1 5 minutes for the control to resume normal operation Also ensure that there is a load at least one tap on the mixed outlet system present while the control is resuming normal operation Note See Start Up and Commissioning procedures of this Manual for more detail 6 If problem persists after conducting the above outlined problem solving procedure contact Powers for replacement sensor s 64 Troubleshooting Error Codes m If the control detects a problem an error will display on the Home screen and from within the System Monitor menu To navigate to the System Monitor menu press PRISM icon unlock the control see detailed Unlock instructions in this Manual for more information and select MONITOR f
55. the SETUP icon from within the Programming menu to access the Setup menu shown below Setup Select the BAS icon from within the Setup menu to access the Building Automation menu shown below Building Automation Back Up Down Enter The default BAS Type is NONE as shown above To change this setting press the Enter icon and the BAS Type adjustment screen will appear as shown below tekmar IntelliStation BAS Integration Manual Depress the YP and Bown icons to scroll through the BAS types and depress the icon to config ure the control to the highlighted type and return to the Building Automation menu Note depending on the BAS Type selected various user configurable items will now appear within the Building Automation menu table of the user definable items is shown below As detailed on the next page depending on the BAS Type selecting the control will display different settings from within the Building Automation menu The Building Automation menu is shown page 42 with the default settings for each of the communication protocols supported by this control BACnet IP BACnet MSTP or Modbus 41 tekmar IntelliStation BAS Integration Manual Additional Info Building Automation Type None control runs in stand alone BAC IP control is con nected to a BACnet IP system BAC MSTP control is connected to a BACnet MS TP system MODBUS control is c
56. tion system Always read and follow the User Guide amp Instruction Manual 3 Attach a 1 hose to the pump inlet hose connection and ensure that the other end of the hose is securely routed to a drain 4 Once you are sure that the hose connection has a safe path to a drain open the pump inlet hose con nect 1 and ensure that the pump inlet isolation valve 2 the mixed outlet isolation valve 3 the hot inlet isolation valve 4 the cold inlet isolation valve 5 and the hose connection valve 6 are in the fully open position 51 Troubleshooting Control Unit Temp amp Pressure Sensor Temp amp Pressure Sensor Recirculation Pump r3 I Electronically Actuated Valve Con gt Temp amp Pressure Sensor 5 From the Home Screen Home Screen Touch the in the bottom left hand side of the display to go to the Programming Menu NOTICE The control automatically locks and returns to the Home Screen if inactive for more than one minute DA Troubleshooting 6 the UNLOCK function icon to go to the Unlock Screen and enter your unique passcode or default 1017 and touch Enter oom M ene e a 4 T mi ANT TO w Back Clear Enter 7 Upon touching Enter you will automatically go to the Programming Menu Programming NOTICE The UNLOCK icon will now read LOCK as the control is now unlocked If
57. touching the screen the user can access the Home screen shown below Home Screen Field 1 Label gt Field 1 Value amp X Field 1 Select Field 2 Label Field 2 Value amp Field 2 Select Programming Menu Access Pump Status Field As shown in the screen shot above there are two fields viewable within the Home screen For instance the Label item and Value for Field 1 and Field 2 shown in the Home screen view above are Field 1 Mixed Outlet Set point and value of 140 F Field 2 Mixed Outlet Temp and value of 140 F The Label item displayed in the fields can be changed by touching the Field Select EB icon to the right of each field value The Labels items available for viewing on the Home screen by touching the Field Select icon are shown in the table below Description Units Description of Controls and Functions Also shown on the Home screen is the Pump Status Field showing if pump is ON or OFF and the icon to access the Programming menu Touching the icon takes the user to the Programming Menu containing six function icons Unlock Setup Monitor Sanitize Home and Toolbox as shown below Programming Menu ramming On the Programming Menu the and BOB icons are the only active icons until the control is unlocked See Unlock the System in the Set up and Programming section of this Manual T
58. tpoint Max Maximum 10F 140 F T J 0 BAS for added security and safety max value 180 F 80 to Mixed Out Mixed Out Setpoint Maximum 10F 140 F Mixed Outlet setpoint max value 180 F A mixed outlet temperature over this amount 1 Mixed Out Setpoint Mixed Out Maximum 150 F will create an error condition and issue a reset 10F to 190 F for the control Sets the Fully Closed valve position Closing Valve Min 0 0 to 10 0 V 0 5V the valve beyond this point has no effect on the output temperature Sets the Fully Open valve position Opening Valve Max 0 0 to 10 0 V the valve beyond this point has no effect on the output temeprature Mix Percent 5V 0 to 100 50 The mixing percentage obtained when the valve position signal is manual set to 5 V This control mode is used when a fixed valve position is desired as when conducting the Self Balancing procedure CAUTION OEF gt UN m Turning this setting to On could create a scald risk See detailed user manual for more infor mation pertaining to the use of this mode Manual Voltage 0 0 to 10 0 V Manual valve position voltage DHW Recirculation pump control mode OFF gt lt ON gt AUTO temperature differential and dead head AUTO protection ON Pump is always on OFF Pump is always off Pump Min On Off Time The minimum time the pump runs or remains off The target t t t which th Return Temp Target 80 F to 180 F 130 F Mer e dE
59. tuator and set it aside 69 Scheduled Testing Inspection and Maintenance Actuator Armature Clamping Nut Support Plate Bolts m Valve Replacement A DANGER BEFORE attempting to open Control Module a certified and qualified elec trician MUST fully de energize and disconnect all electrical power from IntelliStation Perform required LOCK OUT TAG OUT procedures When done reconnection and reen ergizing of IntelliStation MUST be performed by certified and qualified electrician 1 Once de energized the display will become inactive 2 If removing only the valve use Step 4 from the Actuator Removal 3 Disconnect the pressure sensor P1 and outlet sensor FT1 Using a wrench remove the redundant temperature T1 from the pipe fitting 4 Using either the shifting spanner or the gas grip loosen the three unions holding the valve in place see below 70 Scheduled Testing Inspection and Electronically Controlled Valve Mixed Outlet Temperature amp Pressure Sensors Unions 5 If replacing the valve remove the NPT couplers union fittings and actuator mounting plate from the old valve and transfer them to the replacement valve for reinstallation 6 To reinstall the valve simply reverse the above outlined procedure NOTICE If installing Valve and Actuator V amp A combination proceed to Step 8 of actuator installation procedure once the V amp A have been plumbed back into th
60. ys backlight Turn on Power NOTICE Before beginning make sure all ball valves are in the fully open position 1 Turn IntelliStation power ON by turning on the main switch 2 When powered up the display will show a 60 second countdown timer and read Control requires 60 seconds after power up to begin mixing operation Time remaining 30 s NOTICE The control will begin mixing operations automatically after 60 seconds During the 60 seconds the user may adjust setting and configure the control by touching anywhere on the screen to access the PRGM menu If the user does nothing the control will automatically route to the home screen after 60 seconds and begin normal operation 3 The Home Screen will appear Home Screen PRGw Pump OFF Create passcode The IntelliStation comes programmed with a factory default passcode 1017 For added security and to help prevent unauthorized access it is recommended that you create a unique 4 digit passcode as outlined below 1 To select and set your own passcode on the Home Screen touch the icon in the lower left corner as shown below Home Screen 2 You will be directed to the Programming Menu which appears as shown below amming 3 the Programming Menu touch the UNLOCK icon The Unlock function screen w

Installation Instructions - Watts Water Technologies

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