Watts Powers IntelliStation User manual

User Guide & Instruction Manual
IntelliStation
®
Digital Water Mixing
and Recirculation System
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. Visit PowersControls.com with any questions.
Keep this Manual for future reference.
WARNING
!

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, (g) shipping defects
or damage, (h) normal wear and tear, (i) any abuse, misuse, unintended use, failure to
maintain or inspect, (j) any circumstances over which 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. A
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 not 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.

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 selections, and can be remotely
programmed and utilized 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 TEMPORARY/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.

1
Table of Contents
Introduction ..........................................2
Safety Information......................................3
Understanding Safety Information ..........................3
Radio Frequency Warnings & Hazards .......................3
Intellistation Description & Specifications .....................4
Description of Controls & Functions ........................9
Set up and Programming ...............................20
Sanitization .........................................31
Powers Intellistation BAS Integration Manual .................37
Troubleshooting ......................................52
Scheduled Testing, Inspection and Maintenance ...............63

2
Attention Owners and Users
Thank you for purchasing the Powers IntelliStation®. This equipment will provide safe and productive oper-
ation as long as it is installed, set up, used, and serviced in accordance with the instructions 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 over 18 years of age, are adequately trained and supervised, and have read and understand this Manual.
Owners should ensure that no unauthorized personnel come in contact with this equipment.
READ THIS MANUAL carefully, learn
how to install, set up, use, service
and maintain this equipment
correctly, and strictly follow 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 permanent part of the IntelliStation
and be kept available for easy reference by any
user.
If this equipment, or any of its parts, becomes
damaged or needs repair, stop using the
equipment and contact an experienced service
individual 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 equipment.
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.
Product Identification
Please record your product’s identification and purchase information which will help in the event you have
questions or need any service.
Model: Date of purchase:
Seller name / address:

3
Understanding Safety Information
This safety-alert symbol is shown
alone or used with a signal word
(DANGER, WARNING, or CAUTION),
a pictorial and/or a safety mes-
sage to identify hazards and alert
you to the potential for death or
serious personal injury.
Identifies hazards which, if not
avoided, will result in 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.
Identifies practices, actions, or
failure to act which could result in
property damage or damage to the
equipment.
• Read the Manual and all product
labels and follow all safety and other
information.
• Learn how to properly and safely use
the equipment BEFORE installing,
set up, using, or servicing.
• Keep the Manual available for easy
access and future reference.
• Replace missing, damaged, or
illegible Manual and product labels.
• Replacement Manuals available at
PowersControls.com
This pictorial alerts you to the
need to read the manual.
This pictorial alerts you to
scalding, burn and hot water
hazards.
This pictorial alerts you to burn
and hot surfaces hazards.
This pictorial alerts you to
electricity, electrocution, and
shock hazards.
This pictorial alerts you to the
need to perform appropriate Lock
Out/ Tag Out procedures.
WARNING
!
CAUTION
!
NOTICE
DANGER
!
!
WARNING
!
TO AVOID DEATH,
SERIOUS PERSONAL
INJURY, PROPERTY
DAMAGE, OR DAMAGE
TO THE EQUIPMENT:
Reading & Understanding the Manual
Important Safety Information

4
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 controlled thermal eradication protocol.
The IntelliStation®Control 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 com-
plying with all governmental requirements, building and construction codes and standards. It is rec-
ommended 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 distribu-
tion system, proper sizing, maintaining proper water quality/condition, and deciding what tempera-
ture is safe and appropriate for the water distribution users and facility.
IntelliStation Description and Specifications

5
IntelliStation Description and Specifications
The IntelliStation®components
are shown below:
Dimensions
18.90
[480.1]
31.28
[794.5]
50.00
[1270.0]
56.32
[1430.5]
3.08
[78.2]
3.24
[82.2]
7.47
[189.6]
10.65
[270.5]
8.25
[209.6]
4.91
[124.8]
LFIS150 IS SHEET LINE ART
56.00
[1422.4]
61.73
[1568.0]
3.25
[82.6]
2.48
[63.0]
19.93 [506.2]
33.28 [845.3]
8.23
[209.0]
11.80
[299.8]
8.13
[206.4]
5.12
[130.0]
LFIS200 IS SHEET LINE ART
LFIS150 LFIS200
Dimensions are shown ±1/2''
Dimensions in parentheses are in mm
P1
T1
T4
T2
P2
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
Hot
Water
Inlet
Cold
Water
Inlet
Return
Mixed Water
Outlet
To
Boiler

6
Flow Capacity at 50-50 mixed ratio
Pressure Drop Across Valve
Model Min.
System
Draw*
CV
5psi
(34 kPa)
10psi
(69 kPa)
20psi
(138 kPa)
30psi
(207 kPa)
45psi
(310 kPa)
50psi
(345 kPa)
LFIS150 0.50 26.88 60 gpm
227 lpm
85 gpm
322 lpm
120 gpm
454 lpm
147 gpm
556 lpm
180 gpm
681 lpm
190 gpm
719 lpm
LFIS200 0.50 42.70 96 gpm
363 lpm
135 gpm
511 lpm
191 gpm
723 lpm
234 gpm
886 lpm
286 gpm
1083 lpm
302 gpm
1143 lpm
LFIS150DV 0.50 53.57 120 gpm
454 lpm
170 gpm
644 lpm
240 gpm
908 lpm
294 gpm
1113 lpm
360 gpm
1363 lpm
380 gpm
1439 lpm
LFIS200DV 0.50 85.27 192 gpm
727 lpm
270 gpm
1022 lpm
382 gpm
1446 lpm
468 gpm
1772 lpm
572 gpm
2165 lpm
604 gpm
2286 lpm
LFIS200TV 0.50 127.90 288 gpm
1090 lmp
405 gpm
1533 lpm
573 gpm
2169 lpm
702 gpm
2657 lpm
858 gpm
3248 lpm
906 gpm
3430 lpm
IntelliStation Description and Specifications
Specifications
Maximum Operating Pressure ...................................................... 200psi (1379 kPa)
Maximum Hot Water Temperature ........................................................ 200°F (93°C)
Minimum Hot Water Supply Temp.** ................................ 2°F (1°C) Above Set Point
Hot Water Inlet Temperature Range ...................................... 120 – 180°F (49-82°C)
Cold Water Inlet Temperature Range .......................................... 39 – 80°F (4-27°C)
Minimum Flow*** ....................................................................... 0.5 gpm (1.89 lpm)
Outlet Water Temperature Adjustment Range**** ................... 80 – 180°F (27-82°C)
Listing/Compliance ........................ ASSE1017®^, cUPC®^, NSF®^, CSA 24/UL873,
BACnet Testing Laboratories (BTL)
Ambient Temperature ......................................................32°F (0°C) to 104°F (40°C)
Ambient Humidity ......................................................... 0 - 90% RH non-condensing
SUITABLE FOR INDOOR USE ONLY
** 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.
**** Low limit cannot be less than the cold water temperature. For best operation, hot water should be at least
5°F (3°C) above desired set point.
Technical Specifications
Input Power........................ 115/230 V ±10%, 50/60 Hz, 30 VA, 1180 VA fully loaded
Pump relay............................................ 115/230 V: 10/8 FLA, 50/48 LRA Motor Load
Alert relay:..................................................... 30 V (ac/dc) max. 2 A, resistive, Class 2
5 V capacity: ...............................................10 mA maximum each, resistive, Class 2
20 V capacity: .............................................20 mA maximum each, resistive, Class 2
Actuator load:......................................................................................................20 VA
Meets Class B: ..........................................................................ICES and FCC Part 15
Capacity
*With a properly sized pump
^ Listed without re-circulation line & pump
!User is responsible for determining safe and appropriate
temperatures and pressures for system users, guests and facility.