pool/spa control system IntelliTouch Expansion Center Kit Installation Guide IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS
2005 Pentair Water Pool and Spa, Inc. All rights reserved This document is subject to change without notice 1620 Hawkins Ave., Sanford, NC 27330 (919) 566-8000 10951 West Los Angeles Ave., Moorpark, CA 93021 (805) 523-2400 Trademarks and disclaimers IntelliTouch, EasyTouch, IntelliChlor, IntelliFlo, QuickTouch, MobileTouch, SAm, SAL, and FIBERworks, and the Pentair Water Pool and Spa logo are trademarks of Pentair Water Pool and Spa, Inc. Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products. Pentair Water Pool and Spa, Inc. disclaims proprietary interest in marks and names of others. P/N 520471 - Rev A - 09/27/05
i Contents IMPORTANT SAFETY PRECAUTIONS... ii IntelliTouch Expansion Center Kit Contents... 1 About the Installation Guide... 1 Related Manuals... 1 Technical Support... 1 Installation Steps Summary... 2 Expansion Center Enclosure Location... 2 Expansion Center Setup Options... 2 Installing Conduit and Wire... 3 Installing the Outdoor Control Panel... 4 Connecting the Expansion Center Pre-Installed Relays... 5 Installing Auxiliary Relays (Model i5x and i10x)... 6 Connecting the Expansion Center to the Load/Power Center... 7 Connecting the Expansion Center Transformer... 9 System Wiring Diagram... 10 Glossary... 11
ii IMPORTANT SAFETY PRECAUTIONS Important Notice: Attention Installer: This manual contains important information about the installation, operation and safe use of this product. This information should be given to the owner and/or operator of this equipment. WARNING - Before installing this product, read and follow all warning notices and instructions which are included. Failure to follow safety warnings and instructions can result in severe injury, death, or property damage. Call (800) 831-7133 for additional free copies of these instructions. WARNING - Water temperature in excess of 100 degrees Fahrenheit may be hazardous to your health. Prolonged immersion in hot water may induce hyperthermia. Hyperthermia occurs when the internal temperature of the body reaches a level several degrees above normal body temperature of 98.6 F (37 C). The symptoms of hyperthermia include drowsiness, lethargy, dizziness, fainting, and an increase in the internal temperature of the body. The effects of hyperthermia include: 1) Unawareness of impending danger. 2) Failure to perceive heat. 3) Failure to recognize the need to leave the spa. 4) Physical inability to exit the spa. 5) Fetal damage in pregnant women. 6) Unconsciousness resulting in danger of drowning. WARNING - To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times. WARNING - The use of alcohol, drugs, or medication can greatly increase the risk of fatal hyperthermia in hot tubs and spas. WARNING - Control System is intended to control heaters with built-in high limit circuits ONLY. Failure to do so may cause property damage or personal injury. WARNING - Do not use this product to control an automatic pool cover. Swimmers may become entrapped underneath the cover. WARNING - For units intended for use in other than single-family dwellings, a clearly labeled emergency switch shall be provided as part of the installation. The switch shall be readily accessible to the occupants and shall be installed at least 10 feet (3.05 m) away, adjacent to, and within sight of, the unit. CAUTION - Except for listed spa-side remote controls, install a minimum of five (5) feet from the inside wall of the pool and spa.
iii IMPORTANT SAFETY PRECAUTIONS (Continued) General Installation Information 1. All work must be performed by a licensed electrician, and must conform to all national, state, and local codes. 2. Install to provide drainage of compartment for electrical components. 3. If this system is used to control underwater lighting fixtures, a ground-fault interrupter (GFCI) must be provided for these fixtures. Conductors on the load side of the ground-fault circuit-interrupter shall not occupy conduit, junction boxes or enclosures containing other conductors unless such conductors are also protected by a ground-fault circuit-interrupter. Refer to local codes for details. 4. A terminal bar stamped is located inside the supply terminal box. To reduce the risk of electric shock, this terminal must be connected to the grounding means provided in the electric supply service panel with a continuous copper wire equivalent in size to the circuit conductors supplying this equipment (no smaller than 12 AWG or 3.3 mm). The bonding lug(s) provided on this unit are intended to connect a minimum of one No. 8 AWG for US installation and two No. 6 AWG for Canadian installations solid copper conductor between this unit and any metal equipment, metal enclosures or electrical equipment, metal water pipe, or conduit within 5 feet (1.5 m) of the unit. 5. The electrical supply for this product must include a suitably rated switch or circuit breaker to open all ungrounded supply conductors to comply with Section 422-20 of the National Electrical Code, ANSI/NFPA 70.1987. The disconnecting means must be readily accessible to the tub occupant but installed at least 10 ft. (3.05 m) from the inside wall of the pool. 6. Supply conductor must be sized to support all loads. Maximum supply conductor current must be 125 Amps at 125 VAC or 63 Amps at 240 VAC.
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1 IntelliTouch Expansion Center Kit Contents The following items are included in the Expansion Center kit. If any items are missing please contact Technical Support. IntelliTouch Expansion Center Outdoor Control Panel. Includes motherboard and Personality board Power Relays - Models i5x and i10x (5 relays) Wiring Diagram Label - To affix to the inside front door (for models i5x and i10x) Label Sheet - A set of adhesive labels for custom identification (for outdoor control panel buttons). Use a pair of fine-tip tweezers to remove the labels from the sheet (this manual) About this Installation Guide Use the information in this manual to install the IntelliTouch Expansion Center kit contents. Related Manuals For information about configuring an Expansion Center with the IntelliTouch system, refer to the IntelliTouch System User s Guide (P/N 520102) For Load Center and Power Center installation instructions, refer to the Load Center and Power Center Installation Guide (P/N 520100) For additional IntelliTouch installation information, refer to the IntelliTouch Personality Kit Installation Guide (P/N 520101) and the IntelliTouch System User s Guide (P/N 520101) Technical Support Contact Technical Support at: Sanford, North Carolina (8 A.M. to 5 P.M.) Phone: (800) 831-7133 Fax: (919) 566-8920 Moorpark, California (8 A.M. to 5 P.M.) Phone: (800) 831-7133 (Ext. 6502) Fax: (805) 530-0194 Web sites visit www.pentairpool.com and www.staritepool.com
2 Installation Steps Summary Note: Use the following instructions to install and connect additional expansion center enclosures to existing Load Center or Power Center. For Load Center or Power Center installation instructions, refer to the Load Center or Power Center Installation Guide (P/N 520100). The recommended installation steps for the Expansion Kit are as follows: 1 2 3 4 5 Install the Outdoor Control Panel (page 4): Remove the high voltage panel from the Expansion Center enclosure and install the Outdoor Control Panel. Connect Pre-installed Relays (page 5): Connect the relay plugs to the Personality board. The four relays are pre-installed in the Power/Load Center. Installing Auxiliary Relays (page 6): Install and connect the relay(s). For models i5x and i10x. Connecting the Expansion Center to the Load/Power Center (page 7): Connect the 4-wire cable from the Load Center or Power Center to the COM port on the Personality board in the Expansion Center enclosure. Connecting the Expansion Center transformer (page 9): Connect the transformer harness to the Personality board. 6 Affixing the System Wiring Diagram Label (page 9): Affix the wiring diagram on the inside of the front door of the Expansion enclosure (for models i5s, i9+3s, i10+3d only). Expansion Center Enclosure Location All pool equipment including the Expansion Center enclosure, with the exception of the Spa-Side remote, must be located at least 10 ft. from the water s edge. Expansion Center Setup Options An Expansion Center enclosure can be a Load Center or Power Center enclosure. Install the Expansion Center enclosure s near to the main Load Center or Power Center. The Expansion Center can support all of the same high voltage connections as the main load to the Load Center or Power Center. For more information, refer to the Load Center and Power Center Installation Guide (P/N 520100). The Expansion Center enclosure includes COM port connections, and two actuators as does the Load Center or Power Center. The Expansion Center enclosure can be expanded to include up to five actuators (with valve module P/N 520285). Main Load Center (i9+3, i9+3s, i10+3d) Expansion Center (i5x or i10x) Additional Expansion Center Additional Expansion Center (3 maximum)
3 Installing Conduit and Wire Run the appropriate size conduit from the sub-panel to the Expansion Center (see diagram below for knockout locations). Run the appropriate conduit and wire from the main Load Center or Power Center to the Expansion Center. Run a 4-wire communication cable from the Load Center or Power Center to the Expansion Center. Supply cable(s) to the Load Center or Power Center must have a minimum current capacity suitable for the intended load(s). Supply circuit must be protected by suitable breaker rated no higher than 125 AMP. High voltage cover panel attachment screw holes Spring latch Front door removal screw GFCI knockout (approved rainproof cover required) Low voltage raceway knockout Expansion Center Enclosure
4 Installing the Outdoor Control Panel The Expansion Center Outdoor Control Panel includes a motherboard and Personality board. The Personality board is mounted on top of the Motherboard which mounts on the back of the Outdoor Control Panel. The Outdoor Control Panel installs in the top part of the Expansion Center. To install the Outdoor Control Panel in the Expansion Center: 1. Unlatch the front door spring latches, and open the front door of the Expansion Center. 2. Remove the cover-panel screws securing the high voltage cover-panel, and remove it from the enclosure. 3. Mount the Outdoor Control Panel in the top part of the Expansion Center. Secure it with two access screws on the bottom edge of control panel. Once secured, the Outdoor Control Panel can hinge out and down to access the Personality board for low voltage connections. 4. When finished with the relay, and transformer connections (see pages 6 through 9), close the hinged Outdoor Control Panel and secure it with the two access screws. 5. Install the cover-panel and secure it with the two retaining screws. 6. Close the front door of the Expansion Center. Fasten the two spring latches. Outdoor Control Panel Access screw Access screw Cover-panel screw (Cover-panel not shown) Cover-panel screw Retaining screw Retaining screw Expansion Center
5 Connecting the Expansion Center Pre-Installed Relays There are five pre-installed relays in the Expansion Center. To connect the pre-installed relay cable plugs to the Personality board: Route the power relay cable plugs up through the high voltage compartment to the Personality Board. Insert the plug into the two-pin sockets, beginning with AUX1, then AUX2, AUX3, AUX4, and AUX5. For the two-pin socket locations, refer to the diagram shown below and the System Wiring Diagrams for models i5x, and i10x. AUX1, AUX2, AUX3, AUX4, AUX5 Personality Board Feed each relay cable plug up through holes
6 Installing Auxiliary Relays (Model i10x only) Install additional Expansion Center axillary relays as needed. There may be as many as five additional relays. To install a relay: 1. At the Expansion Center, install the relays below the pre-installed relays. Secure in place with two retaining screws. 2. Route the relay cable plug up through the holes into the high voltage compartment to the Personality board. 3. Insert each auxiliary relay plug into the one of the two-pin sockets, beginning with AUX6, AUX7, AUX8, AUX9 and AUX10 on the Personality board. For wiring details, refer to the System Wiring Diagrams for model i10x page 10. Personality Board Relay Retaining Screws Optional Relays (5x)
Connecting the Expansion Unit to the Load/Power Center To connect a 4-wire cable from the Load Center or Power Center to the Personality board in the Expansion enclosure: 7 1. CAUTION - Switch the main power off at the Load Center or Power Center. 2. At the Load Center or Power Center, loosen the two access screws securing the Outdoor Control Panel. Fold down the control panel to access the Personality board. 3. Insert one end of the 4-wire cable that connects the Expansion Center to the main Load center or Power Center into plastic grommet on the bottom of the enclosure and route the wire up through the low voltage raceway to the Personality board. Connect the wires to the COM port (see page 8, step 5, 6, and 7 for details). 4. At the Expansion enclosure, Insert the 4-wire cable into plastic grommet on the bottom of the enclosure and route the wire up through the low voltage raceway to the Personality board. If necessary, for easier access to the raceway, remove the two screws securing the high voltage panel cover, and remove it from the Expansion enclosure. Outdoor Control Panel Access screw Access screw Cover-panel screw (Cover-panel not shown) Cover-panel screw Retaining screw Retaining screw Low voltage raceway Plastic grommet Expansion Center
8 5. Strip back the cable conductors ¼ inch. Insert the wires into the either of the COM PORTS (J7 and J8) screw terminals located on the left side of the Personality board. Secure the wires with the screws. Make sure to match the color-coding of the wires: GND = Black, Green = -DT, Yellow = +DT, and Red = +15 (see diagram below). For wiring details, refer to the Wiring Diagram for models i5x and i10x (page 10). Note: Multiple wires may be inserted into a single screw terminal. 6. Close the Expansion enclosure Outdoor Control Panel and secure it with the two access screws. 7. If removed, install the high voltage panel cover and secure it with the two retaining screws. Personality Board (Left-side) Note: COM Ports can also be used for connection to IntelliChlor and IntelliFlo Personality Board Feed each relay cable plug up through holes
9 Connecting the Expansion Center Transformer To connect the Expansion Center transformer wire harness onto the Personality board: Connect the transformer plug onto connector J2 on the right side of Personality board. The plug is keyed onto the pins so that the six wires point towards back of the board. From left to right the wire colors should be blue, orange, red. For the connector location, refer to the diagram shown below and the System Wiring Diagram (page 10). Note: The transformer terminals can be wired 115 VAC or 230 VAC. Refer to the System Wiring Diagram for models i5x and i10x (see page 10 for wiring connections). Affixing the System Wiring Diagram Label To affix the wiring diagram label on the Expansion Center inside front door: 1. Open the Expansion Center front door. 2. Peel the backing off the wiring diagram label. 3. Position the label in middle of the inside of the front door. Apply even pressure on the surface of the label to secure in place.
10 System Wiring Diagram (For models i5x and i10x)
11 Glossary Expansion Kit: A kit that includes additional auxiliaries to an existing Personality Kit. Requires a Load Center for each Expansion Kit. Feature Circuits: Programmable circuits that may control relays and/or valve actuators. For details see the IntelliTouch Systems User s Guide (P/N 520102) High Voltage Compartment: Large lower right compartment of Load Center for all high voltage wiring including circuit breakers, relays, and GFCI. Indoor Control Panel: This fourteen button remote controller with LCD (liquid crystal display) is wired to the Personality board in the Power/Load Center. The control panel can be wall mounted inside a house to control IntelliTouch Systems. is4: Four function Spa-Side remote. Can be spa wall or deck mounted. is10: Up to ten function spa-side remote with temperature changing capability. Can be spa wall or deck mounted. Load Center: Metal enclosure with power relays, transformer, and circuit breakers. The Load Center is Installed prior to Personality Kit installation. Used for distributing power for controlling IntelliTouch Systems. Also known as the sub-panel. Low Voltage Compartment: Top compartment of Load Center for all low voltage wiring. Low Voltage Raceway: Vertical space in the left side of Power/Load Center for low voltage cabling. MobileTouch Controller: Wireless controller for the IntelliTouch Systems with all the functionality of the Indoor Control Panel. Mud Box: Enclosure to provide mounting features for is10 spa-side remote that is cast into gunite, concrete, or other spa wall/deck construction. Outdoor Control Panel: Control panel with flexible hinge installed in upper portion of Power/Load Center to control IntelliTouch systems. Personality Board: The circuit board mounted on top of the Outdoor Control Panel motherboard. The Personality board defines the system capabilities. Personality Kit: Set of parts to define the capability of a system; may include: Outdoor Control Panel, temperature sensors, actuators, control panel (Indoor or MobileTouch), additional relays, actuators. Power Center: Same as Load Center with the exception of the circuit breaker base. Relay Circuits: The circuits that control the relays on the Personality Board. Connectors on top edge of the circuit board. Terminal Connector: Removable connector that may attach to circuit board with multiple sockets (anywhere from 2 to 12) to receive wires from controllers and sensors; wires held by screw terminals; multiple wires of a small enough gauge (usually 22 AWG) may be coupled to a single socket of a terminal connector. Transceiver: Circuit board with attached antenna that can send and receive radio frequency (wireless) transmissions.
12 Notes
P/N 520471 - Rev A