Installation Source: Intuition-6 Instruction Manual Rev. H , Pages: 11–35
The electrical installation must be performed by qualified personnel and conform to all applicable national, state, and local codes. Live circuits are present inside the controller even when the front panel power switch is OFF.
Enclosure Mounting The controller should be wall mounted at eye level on a vibration-free surface using all four mounting holes.
Mounting Requirements
Use M6 (1/4” diameter) fasteners appropriate for the wall material
Do not install where the display will be exposed to direct sunlight
Consider maximum operating ambient temperature of 131°F (55°C)
Required Clearances Side Clearance Top 2” (50 mm) Left 8” (203 mm) — not required for prewired models Right 4” (102 mm) Bottom 7” (178 mm)
Enclosure Dimensions Dimension Inches Millimeters Width 11.1 282 Height 8.3 211 Depth 5.5 140 Mounting Hole Spacing (W) 8.9 226 Mounting Hole Spacing (H) 6.7 170
Sensor Installation Use these guidelines to place and mount sensors for accurate readings.
General Guidelines Position sensors where:
An active, representative sample of water is available
Sensors can easily be removed for cleaning
Air bubbles will not be trapped within the sensing area
Sediment or oil will not accumulate on the sensing surfaces
In-Line Sensor Mounting For sensors installed in a flow manifold:
Tap off recirculation pump
Connect to the discharge side of the recirculation pump
Ensure adequate flow
Provide minimum 1 GPM flow through the flow switch manifold
Orient flow direction
Flow must enter from the bottom to close the flow switch
Route return line
Return line must go to a point of lower pressure to ensure flow
Install isolation valves
Install isolation valves on both sides for maintenance access
To avoid cracking plastic fittings, use no more than 3 wraps of Teflon tape and thread finger tight plus 1/2 turn only. Do not use pipe dope on flow switch threads.
Submersion Sensor Mounting For sensors submerged directly in the process:
Mount sensors firmly to the tank
Protect cable runs with plastic conduit sealed at the top
Position in an area of good solution movement
Locate for rapid response to treatment chemicals without seeing injection spikes
Sensor-Specific Guidelines Use the sensor-specific notes below to confirm cabling and placement limits.
Maximum cable length: 250 ft (76 m); less than 25 ft (8 m) recommended
Use shielded cable for all extensions
Maintain 6” (15 cm) separation from AC voltage wiring
Electrodeless Conductivity Sensors
Maximum cable length: 120 ft (37 m); less than 20 ft (6 m) recommended
Maintain 6” (15 cm) of sample around the sensor
Keep nearby conductive items consistently positioned
Do not install in the path of stray electrical currents
pH/ORP Electrodes
Maximum cable length: 1000 ft (305 m) with junction box
Install with measuring surfaces always wet (U-trap recommended)
Mount at minimum 5° above horizontal with measuring surface down
Flow velocity must be less than 10 ft/sec (3 m/sec)
Disinfection Sensors
Maximum cable length: 100 ft (30 m) with junction box
Flow cell inlet must be from the bottom (3/4” x 1/4” reducing bushing)
Do not remove the inlet bushing—it provides required flow velocity
Outlet must vent to atmosphere (max 1 atm back pressure)
Install with measuring surface down, at least 5° above horizontal
Boiler Installation Follow these requirements when installing sensors on boiler systems.
Important Notes Review these boiler-side constraints before selecting the sampling location.
Minimum water level must be 4-6” above the skimmer blowdown line
Maintain 3/4” minimum pipe ID from boiler tap to electrode
Use full port valves only—any restriction causes flashing
Keep distance from boiler tap to electrode under 10 ft
Mount electrode in cross fitting on horizontal pipe run
Install flow restriction downstream of electrode and control valve
Blowdown Sizing Use the calculation below to size blowdown for your boiler.
Determine Blowdown Rate Blowdown Rate (lbs/hr) = Steam Production / (Cycles of Concentration - 1)
Example: 100 HP boiler = 3,450 lbs/hr steam
At 10 cycles: 3,450 / (10-1) = 383 lbs/hr blowdownContinuous vs. Intermittent Sampling Use intermittent sampling when:
Boiler operation is intermittent
Required blowdown rate is less than 25% of smallest valve/orifice capacity
Use continuous sampling when:
Boiler operates 24 hours/day
Required blowdown rate exceeds 25% of smallest valve/orifice
Electrical Installation Safety Precautions
Live circuits exist inside the controller even with power switch OFF
Ensure clear access to the disconnecting device
Installation must be by trained personnel only
Proper grounding is required for safety
Power Supply Wiring The controller accepts 100-240 VAC, 50/60 Hz input power.
Prewired Models
Supplied with 8 ft, 18 AWG power cord with USA plug
Hardwired Models Terminal Wire Color (120V) Wire Color (240V) Line (L) Black Brown Neutral (N) White Blue Ground Green Green/Yellow
Relay Output Wiring Powered Relay Models (W6000, W6A00) All six relays switch line voltage to external loads.
Terminal Block Function TB7 Power input (Line, Neutral) TB4 Ground bus TB5 Neutral distribution TB6 Relay outputs R1-R6 (NO contacts)
Connect each load:
Switched line from TB6 relay terminal
Neutral from TB5
Ground to TB4
Total current for all six powered relays must not exceed 6 A. All relays share a common fuse.
Dry contact relays can switch external power sources. Route external power through fused external source terminals.
Terminal Function Wire Color 1 TEMP- White 2 TEMP+ Green 4 RCV Black 7 SHIELD Shield 10 XMT Red
Electrodeless Conductivity Terminal Function Wire Color 1 TEMP- Black 2 TEMP+ Green 3 R-SHLD Shield 5 RCV- Black 6 RCV+ Red 7 X-SHLD Shield 10 XMT+ White 11 XMT- Black
pH/ORP/ISE Sensors Terminal Function Wire Color 1 TEMP- White/Green 2 TEMP+ Green/White 3 IN- White/Orange 4 IN+ Orange/White 5 -5V White/Blue 7 SHIELD Shield 8 +5V Blue/White
Disinfection Sensors Terminal Function Wire Color 3 IN- White 4 IN+ Green 7 SHIELD Shield 8 +5V Red 9 -5V Black
4-20 mA Transmitter Wiring 2-Wire Loop Powered
2-Wire Self-Powered
3-Wire
4-Wire
Terminal Connection 1 (or 7) +24V 4 (or 10) XMTR-
Jumper between terminals 2-3 (or 8-9). Terminal Connection 3 (or 9) XMTR+ 4 (or 10) XMTR-
Terminal Connection 1 (or 7) +24V 4 (or 10) XMTR+ 5 (or 11) COM(-)
Terminal Connection 1 (or 7) +24V 2 (or 8) 24V(-) 3 (or 9) XMTR- 4 (or 10) XMTR+
Input Terminals Function DI 1 TB1: 13, 14, 15 High or low speed counter DI 2 TB2: 13, 14, 15 High or low speed counter DI 3 TB3: 1, 2, 3 State or low speed counter DI 4 TB3: 4, 5, 6 State or low speed counter DI 5 TB3: 13, 14, 15 High or low speed counter DI 6 TB3: 16, 17, 18 State or low speed counter
Connect to DI+ and DI- terminals. Polarity not critical.
Hall Effect Flow Meter Terminal Connection DI+ Signal DI- Ground +9VDC Power
Analog Output Wiring Terminal Block Connection TB1: 16, 17, 18 AO1 (+, -, Shield) TB2: 16, 17, 18 AO2 (+, -, Shield)
Wiring Best Practices Use stranded, twisted, shielded pair wire (22-26 AWG) for:
Flow meter contactor inputs
4-20 mA outputs
Remote flow switches
Terminate shield at the controller end only.
Maintain cable separation
Route sensor cables at least 6” from AC power wiring
Use proper strain relief
Use proper cable glands and strain relief at enclosure entry points
Minimize cable length
Keep cable runs as short as practical to reduce noise pickup
Label all connections
Label all wires for future reference and troubleshooting
Before powering on the controller, verify all wiring connections with a multimeter. Incorrect wiring can damage sensors or controller inputs.
Sources
Intuition-6 Instruction Manual Rev. H Pages 11–35 • February 2024
