KMC Controls BAC-9001CE, BAC-9001, BAC-9021 Installation Manual

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Page 1

BAC-9000 Series VAV Controller

Installation Guide

CONTENTS

Introduction .............................................. 1

Set Drive Hub (45/60°) Rotation Limit ............ 1

Mount Controller ........................................ 2

Connect Sensors and Equipment .................. 3

Connect (Optional) Pressure Sensor.............. 4

Connect (Opt.) Ethernet Network .................. 4

Connect (Optional) MS/TP Network............... 5

Connect Power .......................................... 5

Power and Communication Status ................. 6

MS/TP Network Isolation Bulbs .................... 6

Watch Dog Jumper ..................................... 7

Congure/Program the Controller ................. 7

Sample (BAC-9001) Wiring .......................... 8

Replacement Parts ..................................... 9

Important Notices ...................................... 9

INTRODUCTION

NOTE: The V-clamp nuts 3 should be on top.

Complete the following steps to install a KMC Conquest™ BAC-9000 Series VAV Controller-

Actuator. For controller specications, see the

data sheet at kmccontrols.com. For additional

information, see the KMC Conquest Controller

Application Guide.

SET DRIVE HUB (45/60°) ROTATION LIMIT

NOTE: Complete the steps in this section if

the VAV damper rotation limit is either

60 or 45 degrees.

NOTE: If the VAV damper rotates 90 degrees,

skip this section and go to Mount

Controller on page 2 instead.

1. Push and hold the gear release the drive hub and V-clamp

and rotate

to the left.

2. Turn the controller over.

3. Remove the stop screw location and clean any debris from the threads.

4. Insert the stop screw into the 60 5 or 45 6 stop hole position.

from the storage

KMC Controls, 19476 Industrial Drive, New Paris, IN 46553 / 877.444.5622 / Fax: 574.831.5252 / www.kmccontrols.com

Page 2

NOTE: The drive hub and V-clamp will be

rotated in the same direction in Step 8.

2. Push and hold the gear disengagement lever

on the side of the controller.

5. Tighten the screw until the screw head touches the plastic in the bottom of the recess.

NOTE: Overtightening the screw can cause

compression in the case which may interfere with the controller operation.

3. Rotate the drive hub and V-clamp

in the

same direction that opened the damper.

NOTE: Continue to rotate the drive hub and

V-clamp until they reach a stop.

4. Position the controller over the damper

shaft blocks are easy to access for wiring

so that the color-coded terminal

MOUNT CONTROLLER

NOTE: Install the controller in a metal

enclosure for RF shielding and physical protection.

NOTE: The controller can be installed on a

3/8–5/8 inch (9.5–16 mm) round or 3/8–7/16 inch (99.5–11 mm) square

damper shaft with a minimum length

of 2 inches (51 mm).

1. Manually rotate the damper shaft VAV box to fully open the damper.

on the

NOTE: The black terminals are for power.

The green terminals are for inputs and outputs. The gray terminals (if present) are for MS/TP communication.

5. Finger-tighten the V-clamp nuts

to position

the damper shaft in the drive hub.

BAC-9000 Series Controller Installation Guide 2 921-019-01F

6. Center the mounting bushing 12 in the

mounting tab

Page 3

7. Attach the controller to the VAV box with a

#8 sheet metal screw through the mounting

bushing

8. Evenly tighten the V-clamp nuts

on the

drive hub to 30–35 in-lb.

NOTE: The Ethernet patch cable should be a

maximum of 150 feet (45 meters).

CAUTION

On Conquest “E” models, do NOT plug a cable meant for Ethernet communications into the Room Sensor port! The Room Sensor port powers a NetSensor, and the supplied voltage may damage an Ethernet switch or router.

CONNECT SENSORS AND EQUIPMENT

NOTE: A digital STE-9000 Series NetSensor

can be used for conguring the

controller (see Congure/Program

the Controller on page 7). After the

controller has been congured, an

STE-6010, STE-6014, or STE-6017

analog sensor can be connected to the

controller in place of the NetSensor.

See the relevant installation guide for additional details.

NOTE: See Sample (BAC-9001) Wiring on

page 8 for more information.

1. Plug an Ethernet patch cable

to an STE-9xxx or STE-6010/6014/6017

sensor into the controller’s (yellow

SENSOR

port.

connected

) ROOM

NOTE: Auxiliary VAV equipment such as fans,

heaters, reheat valves, and discharge

air temperature sensors can be connected to the controller.

2. Connect auxiliary VAV equipment to the input

and output green terminal blocks

CAUTION

Do NOT connect 24 VAC to the analog outputs (UO3–UO5 and GNDs)!

BAC-9000 Series Controller Installation Guide 3 921-019-01F

NOTE: Use 24 VAC (only) with triac outputs

(BO6–BO9 with SC).

NOTE: Wire sizes 12–24 AWG can be clamped

in each terminal.

Page 4

NOTE: No more than two (16 AWG) wires can

be joined at a common point.

CONNECT (OPTIONAL) PRESSURE SENSOR

NOTE: Complete the steps in this section

to connect an air flow sensor to the controller.

NOTE: Only the BAC-9021 controller does not

have PRESSURE SENSOR ports. For that model, skip this section.

18 19

CONNECT (OPT.) ETHERNET NETWORK

1. For a BAC-9001CE (only), connect an Ethernet

patch cable

to the 10/100 ETHERNET

port.

CAUTION

NOTE: Use 1/4 inch (6.35 mm) FR tubing.

Tubing should not be longer than 20

feet (6 meters).

1. Remove the black shipping plugs

from the

PRESSURE SENSOR ports.

2. Connect the high pressure tube from the

pressure flow sensor to the HIGH

port on

the controller.

3. Connect the low pressure tube from the

pressure flow sensor to the LOW

port on

the controller.

NOTE: Before May 2016, BAC-9001CE models

had a single Ethernet port now have dual Ethernet ports

. They

enabling daisy-chaining of controllers. See the Daisy-Chaining Conquest

Ethernet Controllers Technical Bulletin on the KMC Partner web site

for more information.

BAC-9000 Series Controller Installation Guide 4 921-019-01F

Page 5

NOTE: Also on the newer models, the Room

Sensor port is yellow

instead of black to help differentiate it from the black Ethernet ports.

22 21

NOTE: The Ethernet patch cable should be

T568B Category 5 (or better) and a

maximum of 328 feet (100 meters) between devices.

see Planning BACnet Networks

(Application Note AN0404A).

NOTE: The EOL switch is shipped from the

factory in the OFF position.

3. If the controller is at either end of a BACnet MS/TP network (only one wire under each

terminal), turn the EOL switch

to ON.

CONNECT (OPTIONAL) MS/TP NETWORK

1. For a BAC-9001 or BAC-9021, connect the network to the gray BACnet MS/TP network

terminal block

NOTE: Use 18 gauge AWG shielded twisted

pair cable with maximum capacitance

of 51 picofarads per foot (0.3 meters)

for all network wiring (Belden cable

#82760 or equivalent).

A. Connect the –A terminals in parallel with

all other –A terminals on the network.

B. Connect the +B terminals in parallel with all

other +B terminals on the network.

CONNECT POWER

NOTE: Follow all local regulations and wiring

codes.

1. Connect a 24 VAC, Class-2 transformer to

the black power terminal block

of the

controller.

A. Connect the neutral side of the transformer

to the controller’s common terminal

⊥

B. Connect the AC phase side of the

transformer to the controller’s phase

∼

terminal

C. Connect the shields of the cable together

at each device using a wire nut or the S terminal in KMC BACnet controllers.

2. Connect the cable shield to a good earth ground at one end only.

NOTE: For principles and good practices

when connecting an MS/TP network,

BAC-9000 Series Controller Installation Guide 5 921-019-01F

NOTE: Connect only one controller to each

transformer with 12–24 AWG copper wire.

NOTE: Use either shielded connecting cables

or enclose all cables in conduit to

maintain RF emissions specications.

Page 6

POWER AND COMMUNICATION STATUS

The status LEDs indicate power connection and network communication. The descriptions below describe their activity during normal operation (at least 5 to 20 seconds after power-up/initialization or restart).

NOTE: If both the green READY LED and the

amber COMM LED remain OFF, check

the power and cable connections to the controller.

Green READY LED

After controller power-up or restart is complete, the READY LED flashes steadily about once per second, indicating normal operation.

Amber (BACnet MS/TP) COMM LED

30 31

Amber ETHERNET LED

 The amber Ethernet LED flashes when the

controller is communicating with a 100BaseT Ethernet network.

 The amber Ethernet LED remains OFF when

the (powered) controller is communicating with the network at only 10 Mbps (instead of 100 Mbps).

 During normal operation, the COMM LED

flickers as the controller receives and passes the token over the BACnet MS/TP network.

 When the network is not connected or

communicating properly, the COMM LED

flashes more slowly (about once a second).

Green ETHERNET LED

NOTE: The Ethernet status LEDs

indicate network connection and communication speed.

 The green Ethernet LED stays ON when the

controller is communicating with the network.

 The green Ethernet LED is OFF when the

(powered) controller is not communicating with the network.

NOTE: If both the green and amber Ethernet

LEDs remain OFF, check the power and

network cable connections.

MS/TP NETWORK ISOLATION BULBS

The two network isolation bulbs 32 serve three functions:

 Removing the (HPO-0055) bulb assembly

opens the MS/TP circuit and isolates the controller from the network.

 If one or both bulbs are ON, the network is

improperly phased. This means the ground potential of the controller is not the same as other controllers on the network. If

this happens, x the wiring. See Connect

(Optional) MS/TP Network on page 5.

 If the voltage or current on the network

exceeds safe levels, the bulbs blow, opening the circuit. If this happens, x the problem and

replace the bulb assembly.

BAC-9000 Series Controller Installation Guide 6 921-019-01F

Page 7

WATCH DOG JUMPER

The watch dog jumper 33 resets the controller if there is a power failure or a communication timeout between the controller and the network.

Never remove the jumper (from the two outer pins).

Cong-

uration



SETUP PROCESS

Programming

(Control Basic)

Web Page Graphics*

KMC

CONTROLS

TOOL

Conquest

NetSensor

Internal con-

guration web

pages in Conquest Ethernet “E” models**

KMC Connect Lite™ (NFC) app***

CONFIGURE/PROGRAM THE CONTROLLER

See the table (on the next page) for the most

relevant KMC Controls tools for conguring, programming, and/or creating graphics for the controller. See the tools’ documents or Help

systems for more information.

NOTE: After the controller has been

congured, an STE-6010/6014/6017

series analog sensor can be connected to the controller in place of an STE-

9000 series digital NetSensor.

NOTE: A BAC-9001CE can be congured by

connecting an HTML5-compatible

web browser to the controller’s default

IP address (192.168.1.251). See

the Conquest Ethernet Controller

Conguration Web Pages Application Guide for more information about the

built-in conguration web pages.

 

**** **** 

 



*Custom graphical user-interface web pages can be hosted on a remote web server, but not in the controller.

**Conquest Ethernet-enabled “E” models with the latest rmware can be congured with an HTML5 compatible web browser from pages served from

within the controller. For information, see the Con

quest Ethernet Controller Conguration Web Pages Application Guide.

***Near Field Communication via enabled smart phone or tablet running the KMC Connect Lite app.

****Full conguration and programming of KMC Conquest controllers is supported starting with TotalControl ver. 4.0.

KMC Connect™ software

TotalControl™ software

KMC Converge™ module for Niagara WorkBench

KMC Converge GFX module for Niagara WorkBench

BAC-9000 Series Controller Installation Guide 7 921-019-01F

Page 8

SAMPLE (BAC-9001) WIRING

(Single Duct VAV, Series Fan Powered with Floating Reheat and Vent Control)

BAC-9001/9001CE Controller

NOTE: For MS/TP models, turn the

End Of Line switch ON at both physical ends of the MS/TP network. Connect the cable shield to earth ground at only one point.

Controller

From

Controller

STE-9521

STE-6010-10

RED BLK

SHLD

RED BLK

SHLD

Ethernet

RDY

COM

ROOM

SENSOR

10/100 ETHERNET

UI3

GND

OFFON

-A

UI4

EOL

BACnet MS/TP

UI5

GND

UI6

UO3

GND

UO4

GND

UO5

HIGH

LOW

BO6

BO7SCBO8

BO9

1/4" (6.35) FR tubing

to flow sensor

PRESSURE SENSOR

H N

Phase

NOTE: For more wiring examples, see the

wiring diagrams that are part of the application library in KMC Connect, Converge, or TotalControl.

CONNECTIONS (SAMPLE)

INPUTS

UI3 = DAT SENSOR ROOM SENSOR

OUTPUTS (Binary/Triac)

BO6 = FAN ENABLE BO7 = OPEN VALVE BO8 = CLOSE VALVE

OUTPUTS (Universal/Analog)

UO4 = FAN SPEED

NETWORK

MS/TP OR ETHERNET

Line

Voltage

24 VAC

(Only)

–

Neutral

POWER

Floating

Reheat

OPEN CLOSECOM

COM

Fan

Start

NOTE: Connect the STE-9xxx (or STE-6010/6014/6017 with no ventilation control) sensor to the Room Sensor port using a max. of 150 feet of Ethernet patch cable.

NOTE: For Ethernet models, connect the

controller to the network with a standard Ethernet patch cord.

NOTE: Analog inputs accept 1K or 10K sensors, 0–12 VDC, or 4–20 mA.

BAC-9000 Series Controller Installation Guide 8 921-019-01F

(Optional)

DAT

STE-1405

10K Ohm

Type 3

Thermistor

NOTE: Use 24 VAC (only) on triac outputs (BO6–BO9 with SC)!

CAUTION: Do NOT connect 24 VAC to the

analog outputs (UO3–UO5 and GNDs)!

Fan

Speed

–

Page 9

REPLACEMENT PARTS

IMPORTANT NOTICES

HPO-0055 Replacement Network

Bulb Module for Conquest

Controllers, Pack of 5

HPO-9901 Conquest Hardware

Replacement Parts Kit

NOTE: HPO-9901 includes the following:

Terminal Blocks DIN Clips

(1) Black 2 Position (2) Small (2) Grey 3 Position (1) Large (2) Green 3 Position (4) Green 4 Position

(2) Green 5 Position (2) Green 6 Position

NOTE: See the Conquest Selection Guide for

more information about replacement parts and accessories.

The material in this document 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 document. In no

event shall KMC Controls, Inc. be liable for any damages, direct, or incidental, arising out of or