Kmc controls BAC-7053, BAC-7051, BAC-7003, BAC-7001 Operation Guide
Installation, Operation,
and
Applications Guide
for
BAC-7000 Series VAV controllers
For applications version 2.2
AN0311ARevision C
KMC Controls
Important notices ©2014, KMC Controls, Inc.
WinControl, NetSensor, and the KMC logo are registered trademarks of KMC
Controls, Inc.
TotalControl, BACstage, and FullBAC are trademarks of KMC Controls, Inc.
All rights reserved. No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any language in any form
by any means without the written permission of KMC Controls, Inc.
Printed in U.S.A.
Disclaimer The material in this manual is for information purposes only. The contents and the
product it describes are subject to change without notice. KMC Controls, Inc. makes
no representations or warranties with respect to this manual. In no event shall KMC
Controls, Inc. be liable for any damages, direct or incidental, arising out of or related
to the use of this manual.
KMC Controls
19476 Industrial Drive
New Paris, IN 46553
U.S.A.
TEL: 1.574.831.5250
FAX: 1.574.831.5252
E-mail: info@kmccontrols.com
Revision C2
BAC-7000 VAV Installation, applications, and operation guide
Contents
Section 1:
Specifications .....................................................................................................................................................6
Accessories and replacement parts ..............................................................................................................10
Safety considerations .....................................................................................................................................11
Section 2:
Set the rotation limits .....................................................................................................................................14
Mounting on a VAV terminal unit ...............................................................................................................16
Wiring compartment ......................................................................................................................................17
Connecting inputs ..........................................................................................................................................18
Connecting outputs ........................................................................................................................................19
Connecting to a NetSensor ............................................................................................................................20
Connecting to an MS/TP network ...............................................................................................................21
Connecting an airflow sensor .......................................................................................................................23
Connecting power ..........................................................................................................................................23
Section 3:
Operation .........................................................................................................................................................25
Controls and Indicators .................................................................................................................................25
Restoring factory settings ..............................................................................................................................28
Maintenance ....................................................................................................................................................30
About the controllers 5
Installing the controllers 13
Operation 25
Section 4:
Assigning network addresses .......................................................................................................................31
Configuring for pressure independent VAV ..............................................................................................32
Configuring for pressure dependent VAV .................................................................................................33
Section 5:
Balancing overview ........................................................................................................................................35
The balancing procedure ...............................................................................................................................36
Section 6:
Input sources ...................................................................................................................................................39
Space setpoints ................................................................................................................................................40
Occupancy and standby ................................................................................................................................40
PID control loops ............................................................................................................................................41
Pressure independent airflow sequence .....................................................................................................41
Pressure dependent temperature control ....................................................................................................41
Changeover ......................................................................................................................................................41
Damper operation ...........................................................................................................................................42
Fan operation ..................................................................................................................................................42
Reheat sequence ..............................................................................................................................................42
Balancing sequence ........................................................................................................................................43
Configuration and set up 31
Balancing with a NetSensor 35
Sequences of operation 39
Section 7:
Pressure independent applications ..............................................................................................................46
Pressure dependent applications ................................................................................................................54
Revision C 3
Applications for BAC-7000 series VAV controllers 45
KMC Controls
Section 8:
Input objects ....................................................................................................................................................61
Output objects .................................................................................................................................................62
Value objects ....................................................................................................................................................62
Loop objects .....................................................................................................................................................63
Control Basic programs .................................................................................................................................64
Reference to objects and programs 61
Revision C4
BAC-7000 VAV Installation, applications, and operation guide
SECTION 1
About the controllers
This section is a description of the KMC Controls BAC-7000 series
VAV controllers. It also introduces safety information. Review this
material before installing or operating the controller.
The
BAC-7000 series VAV controllers
designed for VAV terminal units. An integrated actuator and the supplied programs
make these ideal controllers for single duct pressure independent or pressure
dependent VAV terminal units. The
following features.
are native BACnet, direct digital controllers
BAC-7000 VAV controllers
include the
◆ BACnet MS/TP compliant
◆ Automatically assigns the MAC address and the device instance
◆ On-board airflow sensor for use with a single or multi-point differential
pressure measuring station or pitot tube
◆ Use to control single duct VAV, parallel fan, and reheat
◆ An internal, easy-to-use air balancing program for air balancing
technicians.
◆ No programming required
◆ Configurable with any BACnet operator workstation
The embedded standard applications provide a wide range of single duct VAV
terminal applications for both pressure independent and pressure dependent
(bypass) terminal unit applications.
Pressure independent KMC Controls supplies the BAC-7000 series VAV controllers
for the following pressure independent configurations.
◆ Single duct cooling
◆ Single duct cooling with parallel fan and on/off or modulating reheat
◆ Airflow balancing
Pressure dependent The BAC-7000 series VAV controllers can be set up for the
following pressure dependent (bypass VAV) configurations.
◆ Single duct cooling
◆ Single duct with modulating or On/Off reheat
Revision C 5
About the controllers
Specifications
KMC Controls
Specifications
BAC-7000 specifications are subject to change without notice.
Inputs and outputs
BAC-7000 series VAV controllers are supplied with three universal inputs and three
output connections. The type of output is model dependent. All inputs and outputs
are configured to support the standard application Control Basic programs.
Table 1-1 BAC-7000 series inputs and outputs
Universal
Model
BAC-7001 3 3
BAC-7003 3 1 1 1
BAC-7051 3 3
BAC-7053 3 1 1 1
inputs
Universal
outputs
Triac
outputs
Relay
outputs
Inputs All universal inputs are configured to support
supplied Control Basic programs. They are
configurable as analog, binary, or accumulator
objects to support custom programs.
Key features Standard units of measure.
Overvoltage input protection
Pull–up resistors Switch selectable for none or 10 kΩ.
Connector Removable screw terminal block, wire size
AWG
14–22
Conversion 10–bit analog–to–digital conversion
Pulse Counting Up to 16 Hz
Input range 0–5 volts DC
Outputs, Universal All universal outputs are configured to support
supplied Control Basic programs. They are
configurable as analog or binary objects to support
custom programs.
Key features Output short protection
Standard units of measure
Connector Removable screw terminal block
Wire size 14–22 AWG
Output voltage 0–10 volts DC analog
0–12 volts DC binary
Output current 100 mA per output
Outputs, Relay Relay outputs are configured as binary outputs to
support the supplied Control Basic programs.
Switching Maximum switching 30 volts AC at 2 ampere
Connector Removable screw terminal block
Wire size 14–22 AWG
6
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BAC-7000 VAV Installation, applications, and operation
guide
Outputs, triac Triac outputs are configured as binary outputs to
Switching Optically isolated triac output; maximum switching
Connector Removable screw terminal block
Communications
BACnet MS/TP EIA–485 operating at rates up to 76.8 kilobaud
NetSensor Standard applications compatible with model
About the controllers
Specifications
support the supplied Control Basic programs.
30 volts AC at 1 ampere
Wire size 14-22 AWG
Automatic baud detection
Automatically assigns MAC addresses and device
instance numbers
Removable screw terminal block
Wire size 14–22 AWG
KMD-1161. Custom programming required for other
models.
Connects through RJ–12 connector
Programmable features
Program objects 10 program objects, 4 for standard Control Basic
programs, 6 available for custom programs
PID loop objects 4
Value objects 40 analog and 40 binary
Supported objects See PIC statement for supported BACnet objects
Schedule objects 8 schedule objects
3 calendar objects
Trend objects 8 each of which holds 256 samples
Alarms and events
Intrinsic reporting Supported for input, output, value, accumulator,
trend and loop objects
Notification class objects 8
Memory Programs and program parameters are stored in
nonvolatile memory
Auto restart on power failure
Applications programs KMC Controls supplies the controllers with
programming sequences for single-duct VAV
applications:
◆ Pressure independent cooling with or without
parallel fan or reheat
◆ Pressure dependent single duct cooling with or
without reheat
◆ Airflow balancing
Revision C
7
About the controllers
Specifications
KMC Controls
Airflow sensor The sensor is flow through sensor with dual
platinum film RTD sensors on a ceramic base. The
sensor output is converted to a voltage that
represents 0 to 3000 FPM (15.24 m/s) using 24-inch,
1/4 inch FR tubing and SSS-1000 series flow pickups.
Airflow through the sensor is approximately 1.12
SCFH (32 liters/hour) at 0.25 inches of WC (62.5 Pa)
pressure drop.
The airflow sensor is available as a standard BACnet
analog input object.
Actuator specifications
Torque, minimum 50 in-lb. (5.7 N•m)
Torque, maximum 70 in-lb. (7.9 N•m)
Angular rotation 0 to 95°
Adjustable end stops at 45/60/90° rotation
Motor timing: BAC-7001, 18°/minute at 60 Hz
BAC-7003 15°/minute at 50 Hz
Motor timing: BAC-7051, 60°/minute at 60 Hz
BAC-7053 50°/minute at 50 Hz
Shaft size Fits 0.5 inch (13 mm) round shafts
See Shaft adaptors on page 10 for 0.38 inch shafts.
Regulatory UL 916 Energy Management Equipment
FCC Class B, Part 15, Subpart B
BACnet Testing Laboratory listed
CE compliant
SASO PCP Registration KSA R-103263
Installation
Supply voltage 24 volts AC (–15%, +20%), 50-60 Hz, 8 VA minimum,
15 VA maximum load, Class 2 only, non-supervised
All circuits, including supply voltage, are power
limited circuits.
Weight 2.4 lb. (1.1 kg)
Case material Flame retardant green plastic
Environmental limits
Operating 32 to 120° F (0 to 49° C)
Shipping –40 to 140° F (–40 to 60° C)
Humidity 0–95% relative humidity (non-condensing)
Models
BAC-7001 BACnet AAC for VAV, 18°/minute at 60 Hz
BAC-7051 BACnet AAC for VAV, 60°/minute at 60 Hz
BAC-7003 BACnet AAC for VAV FIU, 18°/minute at 60 Hz
BAC-7053 BACnet AAC for VAV FIU, 60°/minute at 60 Hz
8
Revision C
BAC-7000 VAV Installation, applications, and operation
A
C
B
D
guide
Dimensions
About the controllers
Specifications
Table 1-2 Controller dimensions
ABCD
8.23 in. 4.22 in. 2.25 in. 0.510 in.
209 mm 107 mm 57 mm 13 mm
Revision C
9
About the controllers
Accessories and replacement parts
KMC Controls
Accessories and
replacement parts
Replacement parts
HMO-4531 Non Rotation Bracket- KMD-7001
HPO-0054 Bulbs
HPO-0063 2-PIN KMD jumper (5/Pkg)
Shaft adaptors
HFO-0011 3/8 inch (9.5 mm) shaft adaptor
Airflow sensors Order one of the following for installation on VAV
units without airflow sensor pickup tubes.
SSS-1012 3-5/32 in. length (80 mm) for 1/4 inch O.D. tubing
SSS-1013 5-13/32 in. length (137 mm) for 1/4 inch O.D. tubing
SSS-1014 7-21-32 in. length (195 mm) for 1/4 inch O.D. tubing
SSS-1015 9-29/32 in. length (252 mm) for 1/4 inch O.D. tubing
Power transformer
XEE-6111-40 Single-hub 120 volt transformer
XEE-6112-40 Dual-hub 120 volt transformer
10
Revision C
BAC-7000 VAV Installation, applications, and operation
Danger
Warning
Caution
Note
Detail
guide
About the controllers
Safety considerations
Safety
considerations
KMC Controls assumes the responsibility for providing you a safe product and
safety guidelines during its use. Safety means protection to all individuals who
install, operate, and service the equipment as well as protection of the equipment
itself. To promote safety, we use hazard alert labeling in this manual. Follow the
associated guidelines to avoid hazards.
Danger represents the most severe hazard alert. Bodily harm or death will
occur if danger guidelines are not followed.
Warning represents hazards that could result in severe injury or death.
Caution indicates potential personal injury or equipment or property damage
if instructions are not followed.
Notes provide additional information that is important.
Provides programing tips and shortcuts that may save time.
Revision C
11
About the controllers
Safety considerations
KMC Controls
12
Revision C
BAC-7000 VAV Installation, applications, and operation guide
SECTION 2
Installing the controllers
This section provides important instructions and guidelines for
installing BAC-7000 series VAV controllers. Carefully review this
information prior to installation.
Installing the BAC-7000 series VAV controllers includes the following topics that are
included in this section.
◆ Set the rotation limits on page 14
◆ Mounting on a VAV terminal unit on page 16
◆ Connecting inputs on page 18
◆ Connecting outputs on page 19
◆ Connecting to a NetSensor on page 20
◆ Connecting to an MS/TP network on page 21
◆ Connecting an airflow sensor on page 23
◆ Connecting power on page 23
Revision C 13
Installing the controllers
Caution
Caution
Stop Pins
(1 of 2)
Stop
Selections
Clockwise
(CW)
Pins
Counterclockwise
(CCW)
Pins
Set the rotation limits
KMC Controls
Set the rotation
limits
Before mounting the controller, set the rotational limits with the two supplied stop
pins. These settings limit the shaft rotation in the clockwise (CW) and
counterclockwise (CCW) directions. (See
The maximum amount of shaft rotation is 90°. Placing a stop pin in both 90° slots
allows the actuator the full 90° of travel. Placing a stop pin in any other slot restricts
actuator rotation in the either the CW or CCW direction. Refer to
pin placement and travel. The first number represents the CCW pin and the second
the CW pin.
Illustration 2-1.)
Illustration 2-2 for
To prevent damage to the actuator, always install both stop pins.
Before setting the rotation limits on the controller, refer to the damper position
specifications in the VAV control box to which the controller will be attached.
Setting rotation limits that do not match the VAV damper may result in
improper operation or equipment damage.
14
Illustration 2-1 Controller stop selections
To set the rotational limits, do the following:
1. Turn the controller over so you have access to the back.
2. Locate the two stop pins installed in the back of the unit. (You will find one pin
in a CCW setting and one in a CW setting.)
3. If the stop pins are positioned as required, leave them in place.
4. Identify the limits for the VAV terminal unit damper.
5. Remove one or both pins and place them in the correct slot.
Revision C
BAC-7000 VAV Installation, applications, and operation
guide
Installing the controllers
Set the rotation limits
Illustration 2-2 Controller travel and stop selections
Revision C
15
Installing the controllers
Note
Note
Anti-rotation
bracket
Gear clutch button
Air sensor
inputs
Conduit
plugs
Lock tab
Removable
conduit plate
Access cover Drive hub Status LEDs
Mounting on a VAV terminal unit
KMC Controls
Mounting on a
VAV terminal unit
Mount the controller inside of a metal enclosure. To maintain RF emissions
specifications, use either shielded connecting cables or enclose all cables in conduit.
Mount the controller directly over the damper shaft. A minimum shaft length of 1.75
inch (45 mm) is required. The base of the controller must contact the mounting
surface to allow installation of a bracket to prevent the controller from rotating.
KMC Controls designed the controller for use with either 1/2 inch round or
3/8 inch square damper shafts. For installations with a 3/8 inch round shaft,
use an HFO–0011 shaft adaptor.
Mount the controller close enough to the pitot tubes to keep the tubing length
to be less than 24 inches between the controller’s inputs and the tubes.
16
Illustration 2-3 BAC-7000 VAV series controls and indicators
Mount the controller as follows:
1. Back the set screws out of the drive hub until the shaft can fit through the collar.
2. Place the controller on the damper shaft in the approximate final position.
3. Position the anti-rotation bracket and secure it using #8 or #10 self-tapping
screws. Verify the notch in the bracket securely engages the lock tab on the
controller. (Refer to Illustration 2-3.)
4. Manually position the VAV damper in the fully open position.
5. Press the gear clutch button and rotate the drive hub in the same direction that
opened the damper. Turn the hub until it reaches a rotation limit.
6. Tighten the two set screws in the drive hub to approximately 50–inch pounds
(5.65 N
•m) to lock the hub to the shaft.
Revision C
BAC-7000 VAV Installation, applications, and operation
MS/TP
network
Input
Output
Power
Isolation lamps
Power jumper
RJ–12
Input pull-up
resistors
MS/TP end-of-line
termination
Restart button
guide
Installing the controllers
Wiring compartment
Wiring
compartment
All input, output, power and network connection points are located beneath the
access cover. Remove the two screws that secure this cover to remove the cover.
The controller comes with a removable conduit plate. The plate provides two
inch threaded conduit couplings. If conduit connections are used, note the
0.5
following:
◆ The conduit plate may be removed by removing the two screws that secure the
access cover and removing the cover. Connect the required conduit and replace
the plate in the controller housing.
◆ The plugs may also be sliced to allow wiring to enter the controller with a
minimum of outside contaminates.
Revision C
Illustration 2-4 Connection points inside wiring compartment
17
Installing the controllers
Note
Pull-up
resistors
Off On
Input
terminals
Connecting inputs
KMC Controls
Connecting inputs
The BAC-7000 VAV controllers have three universal inputs. Each input is configured
to support the standard application programs in the controller. By using the pull-up
resistors, either passive or active devices may be connected to the inputs.
KMC supplied Control Basic programs assigns inputs to the following functions.
◆ Connect Input 1 to the space temperature sensor input such as the 10 kΩ.
thermistor in an STE-6000 series sensor.
◆ Connect Input 2 as a setpoint input such as a 0-10 kΩ. dial on an STE-6000
series sensor.
◆ Input 3 is for a 10 kΩ. discharge air temperature sensor.
If a NetSensor is connected to the controller, the standard application
programming will use the temperature and setpoint from the NetSensor and
not from devices connected to Input 1 and Input 2.
Setting the pull–up resistors For passive input signals, such as thermistors or
switch contacts, set the pull-up switch to the On position. See
Illustration 2-5 for the
pull-up switch location.
18
Illustration 2-5 Input terminals and pull-up resistors
Ground terminals Use the GND terminal located next to the input terminals for the
input ground connection. Up to two wires, size 14–22 AWG, can be inserted into the
ground terminal. If more than two wires must be joined at a common point, use an
external terminal strip for the additional wires.
Revision C
BAC-7000 VAV Installation, applications, and operation
Caution
Output
terminals
Output
terminals
guide
Installing the controllers
Connecting outputs
Connecting
outputs
The output terminal configuration for a BAC-7001 and BAC-7051 controllers is
different than the configuration for BAC-7003 and BAC-7053 controllers.
For a listing of the configuration of the controller output objects, see the section
Output objects on page 62.
BAC-7001 and BAC-7051 output connections
BAC-7001 and BAC-7051 controllers provide three universal outputs. These output
are rated for 0-10 volt DC loads. Returns are connected to the GND terminal next to
output O3 as shown in the illustration
BAC-7001 output terminals on page 19.
O1 O2 O3
GND
Illustration 2-6 BAC-7001 output terminals
BAC-7003 and BAC-7053 output connections
The BAC-7003 and BAC-7053 include one single-stage triac, one relay and one
universal output.
O1 T2 RTN2 R3 RTN3
Illustration 2-7 Output terminals
When connecting loads to the triac or relay output, use only the terminal
marked RTN associated with the triac or relay for the 24-volt circuit.
Output O1 This output is a universal output that can be programmed as either an
analog object for modulating reheat. The universal output is rated for 0-10 volt DC
loads. Use the GND terminal on the input connector block for the ground.
Output T2 This is a triac output programmed to switch 24-volt reheat circuits. The
output is rated for 24 volt, 1 ampere loads, and switches on zero crossing. Use the
RTN2 terminal for the T2 load.
Output R3 This is a normally open relay contact programmed to control a 24-volt
fan starting circuit. The relay contacts are rated for 24-volts at 2 amperes. Use RTN3
for the R3 load.
Output 4 Output 4 is internally connected to the actuator motor.
Revision C
19
Installing the controllers
Note
75 feet Max.
Connecting to a NetSensor
KMC Controls
Connecting to a
NetSensor
The Network RJ-12 connector provides a connection port to a NetSensor model
KMD-1161. Link the controller to a NetSensor with a KMC Controls approved cable
up to 75 feet long. See the installation guide supplied with the NetSensor for
complete NetSensor installation instructions.
If a NetSensor is connected to the controller, the standard application
programming will use the temperature and setpoint from the NetSensor and
not from devices connected to Input 1 and Input 2.
-A S
+B
1
GND
Illustration 2-8 Connecting to a NetSensor
20
Revision C
BAC-7000 VAV Installation, applications, and operation
S
+B
-A
S
+B
-A
S
+B
-A
guide
Installing the controllers
Connecting to an MS/TP network
Connecting to an
MS/TP network
BAC-7000 series VAV controllers BACnet MS/TP compliant controllers. For
monitoring and control by building automation system, connect them only to a
BACnet MS/TP network.
Connections and wiring
Use the following principles when connecting a controller to an MS/TP network:
◆ Connect no more than 128 addressable BACnet devices to one MS/TP network.
The devices can be any mix of controllers or routers.
◆ To prevent network traffic bottlenecks, limit the MS/TP network size to 60
controllers.
◆ Use 18 gauge, twisted pair, shielded cable with capacitance of no more than
50 picofarads per foot for all network wiring. Belden cable model #82760 meets
the cable requirements.
◆ Connect the -A terminal in parallel with all other - terminals.
◆ Connect the +B terminal in parallel with all other + terminals.
◆ Connect the shields of the cable together at each controller. For KMC BACnet
controllers use the S terminal.
◆ Connect the shield to an earth ground at one end only.
◆ Connect a KMD–5575 BACnet MS/TP repeater between every 32 MS/TP
devices or if the cable length will exceed 4000 feet (1220 meters). Use no more
than four repeaters per MS/TP network.
◆ Place a KMD–5567 surge surpressor in the cable where it exits from a building.
See Application Note AN0404A, Planning BACnet Networks for additional
information about installing controllers.
Illustration 2-9 MS/TP network wiring
Revision C
21
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