KMC Controls FlexStat BAC-1xx63 Series Installation Manual

Page 1
FlexStat™ BACnet Programmable Thermostats
BAC-1xx63 Series (6 Relays, 3 Analog Outputs)
Installation Guide (6/3 Outputs)

MountingQuick Start

The KMC FlexStat series of intelligent temperature/ humidity-sensing, wall-mounted, thermostat/ controllers are native BACnet Advanced Application Controllers (B-AAC) for use in a BACnet system. The FlexStat simplies networked zone control for common packaged HVAC equipment by including an on-board library of programs that permits rapid conguration of a wide range of HVAC control applications.
To use the FlexStat:
1. Mount and wire the unit (see this Installation Guide).
NOTE: This document gives basic mounting,
wiring, and setup information only. For conguration, programming, operation, and other information, see the KMC Controls web site (www.kmccontrols.com) for the latest documents and rmware. For installation instructions of FlexStats with output congurations other than 6 relays and 3 analog outputs, see that model’s respective installation guide.
2. Congure/program the unit (see the FlexStat
Operation and Application Guides).
3. If necessary, troubleshoot any issues (see the FlexStat Operation Guide).
4. Operate the unit (see the FlexStat Operation Guide).
1.125" (29)
Dimensions in inches (millimeters)
For optimum temperature sensor performance, the FlexStat must be mounted on an interior wall and away from heat sources, sunlight, windows, air vents, and air circulation obstructions (e.g., curtains, furniture). (See the Application Guide for
more information.)
Additionally, for a model with an occupancy sen­sor option, be sure to install it where it will have unobstructed view of the most typical trac area
(see the Application Guide for more information).
If replacing an existing thermostat, label wires as needed for reference when removing the existing thermostat.
1. Complete rough-in wiring at each location prior to thermostat installation. Cable insulation must meet local building codes.
2. Turn the hex screws in the boom and top of
the FlexStat clockwise until they clear the cover. (See Illustration 1.) Pull the cover away from the backplate (mounting base).
3. Route the wiring through the backplate.
4. With the embossed UP toward the ceiling, fasten
the backplate directly to a vertical 2 x 4 inch wall handy-box. (For horizontal or 4 x 4 applications, use the HMO-10000 wall mounting plate.)
5. Make the appropriate connections to the terminal
blocks. (See the Connections and Wiring section.)
6. Place the FlexStat cover over the backplate while
being careful not to pinch or dislodge any wiring. Back the hex screws (counterclockwise)
out of the brackets until they engage the FlexStat cover and hold it in place.
5.551" (141)
4.192" (106)
EIA-485 data
port for quick
network access
Terminal blocks
on backplate for
easy wiring
Cover hex screws
CAUTION
To prevent mounting screw heads from touching the circuit board in the thermostat, use only the mounting screws supplied by KMC Controls. Using screws other than the type supplied may damage the FlexStat.
NOTE: This document is for 6 relay and 3 analog
output BAC-1xx63 series only. See other in-
Illustration 1—Dimensions and Connections
BAC-1xx63 Series (6 Relays, 3 Analog Outputs) 1 Installation Guide
stallation guides for the proper FlexStat series.
Page 2

Connections and Wiring

Wiring Considerations

• Because of the many connections (power, network, inputs, outputs, and their respective grounds or switched commons), be sure wiring is well planned before installation of conduit!
• To prevent excessive voltage drop, use a conduc-
tor size that is adequate for the wiring length! Allow plenty of “cushion” to allow for tran­sient peaks during startup.
• Make sure that conduit for all wiring has ad­equate diameter for all necessary wiring. Using 1-inch conduit and junction boxes is recommend­ed! Use external junction boxes above the ceiling or in another convenient location as needed to make connections that run to the FlexStat’s junction box.
• Using multiple conductor wires for all inputs (e.g., six conductor) and outputs (e.g., 12 conduc­tor) is recommended. Grounds for all the inputs can be combined on one wire.
CAUTION
To avoid damage from ground loops and other communication issues in networked FlexStats, correct phasing on MS/TP network and power connections on ALL the networked controllers is critically important.

MS/TP EOL (End-Of-Line) Termination

The controllers/thermostats on the physical ends of the EIA-485 wiring segment must have end-of-line termination installed for proper network operation. (See Illustrations 2 and 3.) If a FlexStat is at the physi­cal end of the MS/TP network line, set both the EOL termination switches (1 and 2) to On (to the right) on the back of the circuit board. If not on the end, ensure that both switches are O (le).
   
Illustration 2—MS/TP Network End-Of-Line Termination
Pushed Left Pushed Right
OFF
10K
EOL =
1 2
IN3 =
0-12 V
5 6
ON
1 2
1 2
5 6
3 4
5 6
7 8
10K
10K
IN4 =
0-12 V
3 4
IN2 =
0-12 V
7 8
3 4
7 8

MS/TP Wiring

Connect the –A terminals in parallel with all other –A terminals on the network and the +B terminals in paral- lel with all other +B terminals. (See Illustrations 2 and
4.) Connect the shields of the cable (Belden cable #82760
or equivalent) together at each device. Use a wire nut or the S terminal in KMC BACnet controllers. (FlexStats, however, do not have an S terminal.) Connect the cable shield to a good earth ground at one end only.
NOTE: The S terminal in KMC controllers is
provided as a connecting point for the shield. The terminal is not connected to the ground of the controller. When connecting to controllers from other manufacturers, verify the shield connection is not connected to the controller’s ground.
For more information on principles and good practic­es when connecting an MS/TP network, see Planning BACnet Networks (Application Note AN0404A).
Illustration 3—EOL and Pull-Up Switch Resistor Positions
NOTE: IN1 is the room temp.
sensor AI1
NOTE: SC = Switched
(Relay) Common
BACnet MS/TP Network
Inputs
(Wiring Inputs and Outputs Dependent on Application)
Common/–/C
24 VAC
Illustration 4—(BAC-1xx63C) Terminals and Connections
Phase/ /R
+B
–A
IN4
IN3
GND
IN2
(Wiring Cutout in Backplate)
Outputs
Analog 9
GND 7–9
Analog 8
Analog 7
Relay 6
SC 4–6
Relay 5
Relay 4
Relay 3
SC 1–3
Relay 2
Relay 1
BAC-1xx63 Series (6 Relays, 3 Analog Outputs) 2 Installation Guide
Page 3

Input Connections

Output Connections

Passive input devices require pull-up resistors in the circuit. For passive input devices (e.g., switch contacts and Type III 10K ohm thermistors) on IN2 through IN4, set the pull-up switches on the back of the circuit board to the 10K position. For active voltage devices, set the switches to the 0–12 VDC position. (See Illustrations 3 and 4.)
NOTE: Unlike the EOL switch pairs (1-2), the
INPUT switch pairs (3-4, 5-6, and 7-8) must NOT have both switches set to the le or both set to the right—if switch 3 is
set to the le, for example, switch 4 must be set to the right (or vice versa). ALL the
input pull-up resistor switch pairs must be fully latched in either 10K Ohm or 0–12 VDC positions even if a switch pair has no input connected! A single incorrect
switch position may cause errors in mul­tiple inputs.
NOTE: For more information on wiring specic
applications (AHU, FCU, HPU, RTU), see the Applications section starting on page
4. (These applications are the packaged
programs selectable from the Advanced > Application menu in the BAC-1xx63C mod­els.) See also the FlexStat Application Guide on www.kmccontrols.com.
NOTE: FlexStat inputs do not support 1K ohm
RTDs. To use a 4–20 current loop input or map analog inputs as binary values, see the FlexStat Application Guide.
Connect the device under control between the desired output terminal and the related SC (Switched Com- mon for relays) or GND (Ground for analog outputs) terminal. (See Illustration 4). For the bank of three relays, there is one Switched (relay) Common connec­tion (in place of the GND terminal used with analog outputs). (See Illustration 5).
One Switched Common Connection Per Bank of Three Normally Open Relays
Illustration 5—Switched (Relay) Common and Relays
Relay 3 (or 6)
SC 1–3 (or 4–6)
Relay 2 (or 5)
Relay 1 (or 4)
Do not aach a device that draws current exceeding the FlexStat’s output capacity:
• Maximum output current for individual ANA­LOG outputs (7–9) is 20 mA @ 12 VDC (each).
• Max. output current is 1 A for individual RELAYS @ 24 VAC/VDC or a total of 1.5 A per bank of 3 relays (relays 1–3 and 4–6).
For example, KMC REE-3111/3112 relays could be connected to the analog outputs, but REE-
3211/3221/3213 relays would exceed the FlexStat’s analog output capacity (although the REE-3211 can
be used with the FlexStat’s internal relays 1–6 as shown in the following applications pages).
FlexStat relays 1–6 are NO, SPST (Form “A”). (To emulate binary outputs with the analog outputs, set the output voltage to be either 0 or 12 VDC in Control
Basic.)
CAUTION
Relays are for Class-2 voltages (24 VAC) only. Do not connect line voltage to the relays!
CAUTION
Do not mistakenly connect 24 VAC to an analog output ground. This is not the same as a relay’s switched common. See the backplate’s terminal label for the correct terminal.
BAC-1xx63 Series (6 Relays, 3 Analog Outputs) 3 Installation Guide
Page 4

Power Connection

The FlexStat requires an external, 24 volt, AC power source. Use a KMC Controls Class-2 transformer to supply power. Connect the transformer’s neutral lead to the 24 VAC Common/–/C terminal and the AC phase lead to the 24 VAC Phase/
~/R terminal.
(See Illustration 4.) Power is applied to the FlexStat when the transformer is plugged in.
KMC Controls recommends powering only one con­troller/thermostat from each transformer. If installing a FlexStat in a system with other controllers/thermo­stats powered from a single transformer, however, phasing must be correct and the total power drawn from the transformer must not exceed its rating.

Accessories

HMO-10000 Horizontal or 4 x 4 handy box wall
mounting plate, light almond
HMO-10000W HMO-10000 in white
HPO-0044 Replacement cover hex screw
HTO-1103 FlexStat rmware ash upgrade
kit
KMD-5567 Network surge suppressor
KMD-5575 Network repeater/isolator
KMD-5576 EIA-485 to USB Communicator
KMD-5624 PC data port (EIA-485) cable
(FlexStat to USB Communica­tor)—included with the KMD­5576 (buy for third-party EIA-232 interfaces)
SP-001 Flat blade and hex end screw-
driver (with KMC logo) for cover hex screws
XEE-6111-040 Transformer, 120-to-24 VAC, 40
VA, single-hub
XEE-6112-040 Transformer, 120-to-24 VAC, 40
VA, dual-hub
Configuration
To congure the FlexStat, navigate the menus and change seings by pressing a combination of buons. Press the Right (Menu) buon and then the:
• Enter buon to select and/or exit value editing.
• Up/Down buon to move among entries (up/ down lines).
• Le/Right buon to move among value elds (le/right spaces).
• Le buon to return to the Home screen.
Humidity and motion sensor options are dependent on the FlexStat model. For operation, conguration, troubleshooting, and other information, see the FlexStat Operation Guide.
MAINMENU ABOUT
ADVANCED
ALARM DATE/TIME SCHEDULE SETPOINTS SYSTEM
Illustration 6—Configuration Screens
NOTE: Applications on pages 5–9 are the packaged
programs selectable from the Advanced > Application menu in the BAC-1xx63C (only) models. Other FlexStat models have other applications. Humidity and motion sensor options are dependent on the FlexStat model.
ADVANCED
APPLICATION
CBPROGRAMS COMMUNICATION DATE/TIME DEVICE INPUTS LIMITS
(See
menus
on the
following
pages)
BAC-1xx63 Series (6 Relays, 3 Analog Outputs) 4 Installation Guide
Page 5

Applications

Air Handler Unit (AHU)—
Modulating Heat and Modulating Cool
NOTE: See also the RTU section
for 2-stage options.
REE-3211 Multi-Voltage Relay
XEE-6311-075/6311-100 Transformer
MEP-5372/7252/7552/7852 Fail-Safe Actuators
XEE-6311-075 Transformer
VEP-45xxB895/VEB-43xxxBDL Valves with MEP-5372 Fail-Safe Actuators
AHU LAYOUT
APPLICATION DEGREESSCALE:°F
APP:
AIRHANDLER
ADDITIONALSETUP
ADDITIONALSETUP
DAMPER
FAN HUMIDITY SENSORS VALVE
Input Terminals AHU Input Connections BACnet Objects
IN4 Opt. Outside Air Temp. (OAT)* AI4
IN3 Opt. Mixed Air Temp. (MAT)* AI3
GND Ground
IN2 Optional FST or DAT** AI2
*When using optional Outside Air Damper, must also have MAT/OAT inputs (typically 10K, Type III thermistors). Ensure pull-up resistor switch positions are set properly—see Illustration 3 on page 2. **Fan Status (FST) or Discharge Air Temperature (DAT) is an optional, selectable input. Ensure pull-up resistor switch positions are set properly (10K position) for the relay, switch, or Type III thermistor.
CSE-1102 Air Differential
Pressure Switch
STE-1402 Duct Sensor, Type III
NOTE: EITHER FAN STATUS (FST) OR
DISCHARGE AIR TEMP (DAT) CAN BE USED ON IN2, BUT NOT BOTH.
STE-1416 Duct Averaging Temp. Sensor
STE-1451 Outside Air Temp. Sensor
Output
Terminals
Analog 9 Outside Air Damper (OAD/RTD)* AO9
GND Ground (for analog output terminals 7–9)
Analog 8 Heating Valve (HTV) AO8
Analog 7 Cooling Valve (CLV) AO7
Relay 6 (BO6)
SC 4–6
Relay 5 (BO5)
Relay 4 (BO4)
Relay 3 (BO3)
SC 1–3 24 VAC (for relay terminals 1–3)
Relay 2 (BO2)
Relay 1 Fan BO1
*If optional Outside Air Damper is used, must also have MAT/OAT inputs.
AHU Output Connections
(Modulating)
BACnet Objects
NOTE: Connections and menus reect rmware
version R1.3.0.4 or later.
BAC-1xx63 Series (6 Relays, 3 Analog Outputs) 5 Installation Guide
Page 6
Heat Pump Unit (HPU)—
1 or 2 Compressors with Auxiliary and Emergency Heat
CAUTION
Relays are for Class-2 voltages (24 VAC) only. Do not connect line voltage to the relays!
Do not mistakenly connect 24 VAC to an analog output ground.
XEE-6311-075 or XEE-6311-100 Transformer
HPU LAYOUT
MEP-5372/7252/7552/7852 Fail-Safe Actuators
CSE-1102 Air Differential
Pressure Switch
STE-1402 Duct Sensor, Type III
NOTE: EITHER FAN STATUS (FST) OR
DISCHARGE AIR TEMP (DAT) CAN BE USED ON IN2, BUT NOT BOTH.
STE-1416 Duct Averaging Temp. Sensor
STE-1451 Outside Air Temp. Sensor
NOTE: WIRE TO “O” TERMINAL IF
REVERSING VALVE IS ENERGIZED IN COOLING MODE; WIRE TO “B” TERMINAL IF REVERSING VALVE IS ENERGIZED IN HEATING MODE.
NOTE: Although
typical terminal code leers are shown, check the schematics of your unit for wiring details.
APPLICATION DEGREESSCALE:°F
APP:
HEATPUMP OPT:1STAGE ADDITIONALSETUP
ADDITIONALSETUP
AUXHEAT
DAMPER FAN HUMIDITY SENSORS VALVE
NOTE: To see Humidity options in the Additional
Setup menu, select an Aux. Heat option other than None (the default).
Input Terminals HPU Input Connections BACnet Objects
IN4 Opt. Outside Air Temp. (OAT)* AI4
IN3 Opt. Mixed Air Temp. (MAT)* AI3
GND Ground
IN2 Optional FST or DAT** AI2
*When using optional Outside Air Damper, must also have MAT/OAT inputs (typically 10K, Type III thermistors). Ensure pull-up resistor switch positions are set properly—see Illustration 3 on page 2. **Fan Status (FST) or Discharge Air Temperature (DAT) is an optional, selectable input. Ensure pull-up resistor switch positions are set properly (10K position) for the relay, switch, or Type III thermistor.
Output
Terminals
Analog 9 Outside Air Damper (OAD/RTD)* AO9
GND
Analog 8 (AO8)
Analog 7 (AO7)
Relay 6 W2/E Emergency Heat (Optional) BO6
SC 4–6 R 24 VAC (for relay terminals 4–6)
Relay 5 W Auxiliary Heat (Optional) BO5
Relay 4 Y2 Compressor 2 (Optional) BO4
Relay 3 Y1 Compressor 1 BO3
SC 1–3 R 24 VAC (for relay terminals 1–3)
Relay 2 O/B
Relay 1 G Fan BO1
*If optional Outside Air Damper is used, must also have MAT/OAT inputs.
Typical
Terminal
Codes
HPU Output Connections
Ground
(for analog output terminals 7–9)
Reversing Valve
(see O/B Note in schematic)
BACnet Objects
BO2
BAC-1xx63 Series (6 Relays, 3 Analog Outputs) 6 Installation Guide
Page 7

Roof Top Unit (RTU)— 1 or 2 Heat and 1 or 2 Cool

NOTE: Terminal connections and menus
reect rmware version R1.3.0.4 or later. (Relay 3 and 4 were swapped in versions earlier than R0.0.0.0.)
XEE-6311-075 or XEE-6311-100 Transformer
RTU 2H/2C LAYOUT
MEP-5372/7252/7552/7852 Fail-Safe Actuators
CSE-1102 Air Differential
Pressure Switch
NOTE: EITHER FAN STATUS (FST) OR
DISCHARGE AIR TEMP (DAT) CAN BE USED ON IN2, BUT NOT BOTH.
STE-1416 Duct Averaging Temp. Sensor
STE-1451 Outside Air Temp. Sensor
RC AND RH TERMINALS ARE PRESENT:
IF BOTH WIRE RC TO SC 1-3 AND RH TO SC 4-6.
IF ONLY ONE “R” TERMINAL IS PRESENT: WIRE BOTH SC 1-3 AND SC 4-6 TO R.
STE-1402 Duct Sensor, Type III
NOTE: This was 2 Heat and 2 Cool in
rmware R1.3.04 and earlier. Multistage was added later.
APPLICATION DEGREESSCALE:°F
APP:
ROOFTOP OPT:1H/1C ADDITIONALSETUP
ADDITIONALSETUP
DAMPER
FAN HUMIDITY SENSORS
NOTE: Although typical terminal code leers are
shown, check the schematics of your unit for wiring details.
Input Terminals RTU Input Connections BACnet Objects
IN4 Opt. Outside Air Temp. (OAT)* AI4
IN3 Opt. Mixed Air Temp. (MAT)* AI3
GND Ground
IN2 Optional FST or DAT** AI2
*When using optional Outside Air Damper, must also have MAT/OAT inputs (typically 10K, Type III thermistors). Ensure pull-up resistor switch positions are set properly—see Illustration 3 on page 2. **Fan Status (FST) or Discharge Air Temperature (DAT) is an optional, selectable input. Ensure pull-up resistor switch positions are set properly (10K position) for the relay, switch, or Type III thermistor.
Output
Terminals
Analog 9 Outside Air Damper (OAD/RTD)* AO9
GND
Analog 8 (AO8)
Analog 7 (AO7)
Relay 6 (BO6)
SC 4–6 RH/R 24 VAC (for relay terminals 4–6)
Relay 5 W2 Heat 2 (Optional) BO5
Relay 4 W1 Heat 1 BO4
Relay 3 Y2 Cool 2 (Optional) BO3
SC 1–3 RC/R 24 VAC (for relay terminals 1–3)
Relay 2 Y1 Cool 1 BO2
Relay 1 G Fan BO1
*If optional Outside Air Damper is used, must also have MAT/OAT inputs.
Typical Terminal
Codes
RTU Output Connections
(1 or 2 H and 1 or 2 C)
Ground
(for analog output terminals 7–9)
BACnet Objects
BAC-1xx63 Series (6 Relays, 3 Analog Outputs) 7 Installation Guide
Page 8
Fan Coil Unit (FCU)—
2 or 4 Pipe, Modulating or 2 Position
FCU 4-PIPE
MODULATING LAYOUT
(See the FCU—Other Options section on the next page for more options)
CSE-1102 Air Differential
Pressure Switch
4-PIPE MODULATING OPTION
XEE-6311-050 Transformer
VEP-45xxB745/ VEB-43xxxBCK
MEP-4002 0–10
VDC Actuators
NOTE: EITHER FAN STATUS (FST) OR
DISCHARGE AIR TEMP (DAT) CAN BE USED ON IN2, BUT NOT BOTH.
Valves with
STE-1402 Duct Sensor, Type III
NOTE:
Humidity and occupan­cy sensor options are dependent on FlexStat model.
Input Terminals FCU Input Connections BACnet Objects
IN4 (AI4)
IN3 Supply Water Temp. (W-TMP)* AI3
GND Ground
IN2 Optional FST or DAT** AI2
*Input for Supply Water Temp is typically a 10K,Type III thermistor. Ensure pull-up resistor switch positions are set properly—see Illustration 3 on page 2. **Fan Status (FST) or Discharge Air Temperature (DAT) is an optional, selectable input. Ensure pull-up resistor switch positions are set properly (10K position) for the relay, switch, or Type III thermistor.
APPLICATION DEGREESSCALE:°F
APP:
FANCOIL OPT:4–PIPE ADDITIONALSETUP
ADDITIONALSETUP
FAN
HUMIDITY SENSORS VALVE
NOTE: To see Humidity options in
the Additional Setup menu, select the 4-Pipe option.
REE-3211 Multi-Voltage Relays
Output Terminals
(BAC-1xxx63C)
Analog 9 (AO9)
GND
Analog 8
Analog 7
Relay 6 (BO6)
SC 4–6 24 VAC (for relay terminals 4–6)
Relay 5
NOTE: Do not use REE-3211s with analog outputs! See Output Connections on page 3.
BAC-1xx63 Series (6 Relays, 3 Analog Outputs) 8 Installation Guide
Relay 4
Relay 3 Fan 3 BO3
SC 1–3 24 VAC (for relay terminals 1–3)
Relay 2 Fan 2 BO2
Relay 1 Fan 1 BO1
*If optional Outside Air Damper is used, must also have MAT/OAT inputs.
FCU Output Connections
2-Pipe 4-Pipe
(for analog output terminals 7–9)
Valve,
Proportional (VLV)
Valve,
2-Position (VLV)
Ground
Heat Valve,
Proportional (HTV)
Cool Valve,
Proportional (CLV)
Heat Valve,
2-Position (HTV)
Cool Valve,
2-Position (CLV)
BACnet Objects
AO8
AO7
BO5
BO4
Page 9

Fan Coil Unit (FCU)—Other Options

Additional Resources

NOTE: See the FCU—Overview section on the
previous page for the 4-Pipe Modulating option and the general schematic.
(4-PIPE 2-POSITION FCU OPTION)
XEE-6311-050 Transformer
BL U (V EP Series) or BLK (VEZ Series
BR N (V EP Series) or RED (VEZ Series
VEP-1xxx0186/VEZ-4xxxxMBx
Valves with 24 VAC Actuators
(See Wire
Colors
Above
)
N.O.
)
)
N.C.
The latest support les are always available on the KMC Controls web site (www.kmccontrols.com). To see all available les, you will need to log-in to the Partners site.
For specications, see the FlexStat Data Sheet.
For operation, conguration, troubleshooting, and other information, see the FlexStat Operation Guide.
For additional wiring, application, and program­ming information, see the FlexStat Application Guide.
For additional instructions on programming, see the Help system for BACstage or TotalControl.
(2-PIPE MODULATING FCU OPTION)
XEE-6311-050 Transformer
VEP-45xxB745/ VEB-43xxxBCK
MEP-4002 0–10
STE-1454 Temp. Sensor
(2-PIPE 2-POSITION FCU OPTION)
XEE-6311-050 Transformer
VEP-1xxx0186/VEZ-4xxxxMBx
Valve with 24 VAC Actuator
BL U (V EP Series) or BLK (VEZ Series
BR N (V EP Series) or RED (VEZ Series
STE-1454
Temp. Sensor
)
)
Valve with
VDC Actuator

Important Notices

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 related to the use of this document.
KMC Controls, Inc.
19476 Industrial Drive
PO Box 497
New Paris, IN 46553
574.831.5250; Fax 574.831.5252
www.kmccontrols.com; info@kmccontrols.com
BAC-1xx63 Series (6 Relays, 3 Analog Outputs) 9 Installation Guide
© 2010 KMC Controls, Inc. 913-019-01I
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