TSI Instruments 8680 SUPERFLOW, SUREFLOW 8681 Installation Instructions Manual

MODEL 8680 SUREFLOW™

ADAPTIVE OFFSET CONTROLLER

INSTALLATION INSTRUCTIONS

WARNING: The Model 8680 Adaptive Offset Controller must be wired to 24 VAC only. Wiring the unit to

110 VAC will cause serious unit damage and void the warranty.

These installation instructions guide the installer through the installation of the TSI Model 8680 SureFlow™
Adaptive Offset Controller and all TSI options. Some options may not have been provided by TSI, so please
review those product installation instructions. Please read these instructions thoroughly before beginning
installation.

Figure 1: Typical Laboratory Installation

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TSI and TSI logo are registered trademarks of TSI Incorporated.
SureFlow is a trademark of TSI Incorporated.

Component List

NOTE: There are a large variety of options that can be installed with the Adaptive Offset Controller. The

system you are installing may not have all components or quantity of components listed below.

Only TSI-supplied devices, listed below, are covered in these installation instructions. Please refer to

the manufacturer’s installation instructions for proper installation of non TSI devices.

Adaptive Offset Controller

Part Number Qty Description

800227 1 Digital Interface Module / Adaptive

Offset Controller module (DIM /
AOC)

800326 1 Pressure sensor

800248 1 Sensor cable

800420 1 Transformer

800414 1 Transformer cable

1901057 2 Intumescent ring

2923020 1 Fire sealant

Flow Stations (each unit)

Part Number Qty Description

N/A 1 Flow station - sized to duct

(Air Monitor brand)

804139 1 Pressure Transducer (MAMAC

brand)

800420 1 Transformer

800414 2 Transformer cable - second cable is

for flow station output.

Dampers/Actuators (each unit)

Part Number Qty Description

N/A 1 Damper - sized for duct

800420 1 Transformer

800414 2 Transformer cable - second cable is

for control signal.

800360 1 Electric actuator

or

800119 1 E/P Interface

800116 1 Pneumatic operator

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Digital Interface Module Installation

1. Select the mounting location of the Digital

Interface Module (DIM). The construction plans
normally show the mounting location. If no
location is specified, the unit is typically installed
as shown in Figure 1, either in the laboratory or
in the hallway.

2. Install a standard double gang electrical box

(4” x 4”).

3. Slide the DIM cover to the right and remove three

screws holding the electronics to the base
(Figure 2). Remove base.

4. Screw the base to the 4” x 4” electrical box

(screws not included). The base’s “THIS SIDE UP”

arrow must be pointing towards the ceiling.

5. Refer to the wiring diagrams for proper wiring

(Figures 12 and 13). The cables are terminated
both at the DIM, and at the appropriate device.

6. Carefully push the wires into the electrical box

and mount the DIM. Re-install the three screws to
hold DIM firmly to base. Install cover and slide
left to hide display.

Figure 2: Digital Interface Module Mounting

NOTE: Two screws are hidden behind the cover when

full open. The cover will slide to the right approximately
2 inches until a stop is hit. Pull cover to completely
remove from electronics and expose the screws.

Wiring

WARNING: DO NOT connect more than

24 VAC to any terminal.

DO NOT apply voltage to the RS-485 output,
analog output, or control output. Severe
damage may occur to the unit if voltage is
applied.

WARNING: Each damper/actuator and flow
station has a separate transformer that must be
installed. DO NOT wire more than one device
per transformer.

1. Remove the connectors from the back of DIM.

2. Refer to Figures 12 and 13 wiring diagram for

pressure sensor, DIM, TSI Damper/actuator, and
TSI flow station wiring. Refer to Figure 14 wiring
diagram for transformer wiring.

NOTE: If additional options need to be wired, or
non TSI components need wiring, refer to
building prints for proper wiring diagram.

3. Strip 1/4” to 3/8” insulation from the wires.

Twist stranded wire to eliminate loose strands.

4. Insert wire into connector and tighten.

5. Insert connector into proper receptacle.

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Pressure Sensor Installation

This product is classified by Underwriters Laboratories, Inc.® for use in through-penetration
firestop systems. See UL fire resistance directory.

The pressure sensor (P/N 800326) is typically
installed above the main entrance to the laboratory
(Figure 3).

WARNING: 800326 pressure sensor must be
mounted through the wall between the controlled
space (laboratory) and referenced space
(hallway), exactly as shown in Figure 4.

1. Determine pressure sensor location (Figures 3

and 4). Pressure sensor typically mounts in the
reference space, and the dummy housing mounts
in the laboratory.

NOTE: Pressure sensor is not symmetrical. If
sensor is to be centered over hallway door,

measure one inch to the left of center for 2¼”
hole. Dummy sensor will be 2” off center on other

side of wall.

2. The pressure sensor must be orientated on the

wall as shown in Figure 5. Looking at the
mounted sensor, sensor hole is on the left
(2¼”) and wire hole is on the right.

Figure 3: Pressure Sensor and DIM Typical

Installation

3. Drill a 2¼-inch hole through each side of the wall

to accept the sensor tube.

4. Drill a 7/8-inch hole on the side of the wall that

the pressure sensor will be mounted. This hole is
for the six-conductor sensor cable. Refer to
Figure 5 for a hole mounting pattern.

5. Slide sensor cover to right and remove screw that

holds the sensor base to the pressure sensor
(Figure 5). Remove pressure sensor and store in a
safe place.

6. From the side of the wall the sensor will be

mounted, slide the sensor tube through the wall.
Mark the tube where it is flush with wall. Remove
sensor tube and cut tube 1/8-inch shorter than
flush marking.

Figure 4: Cutaway View of Mounted Pressure Sensor

NOTE: If 12” sensor tube is not long enough, add

a 1” to 2” adapter and extend with 2" OD tube.
The base of the dummy housing will need to be
drilled out to accommodate 2” tube. DO NOT
extend sensor tube with 1” tubing.

7. From the side of the wall the sensor will be

mounted, slide the sensor tube through the wall.
Slide the dummy base over the end of the tube.
Screw the pressure sensor base and dummy base
to the wall (Figure 6).

-4-

8. Refer to the wiring diagrams for proper wiring

(Figures 12 and 13). The sensor cable is
terminated at the pressure sensor, and at the
DIM.

9. Insert fire protection sealant (provided) into 7/8”

wire hole to seal.

10. Install and screw the pressure sensor and dummy

cover onto the bases. Slide covers to the left to
hide the sensor. Finished installation should look
as shown in Figure 6.

WARNING: DO NOT touch the sensor element in
the pressure sensor. DO NOT run wires through
the air passage. Doing so will damage the sensing
element.

Figure 5: Pressure Sensor Orientation and

Figure 6: Pressure Sensor Mounting

Mounting Template

-5-

Flow Station Installation

1. Select the mounting location of the flow station.

The construction plans normally show the
mounting location. If no location is specified, then
typically the flow station is installed upstream of
the damper actuator.

WARNING: Figure 7 gives the minimum
straight length duct diameters required for
the flow station to operate correctly.

TSI recommends installing the flow station
upstream of the damper (before). TSI does
not recommend installing the flow station
downstream (after) the damper. If the flow
station must be placed downstream, a
minimum of 4 straight duct lengths between
the damper and flow station is required. In
addition, the flow station must be rotated 90
(perpendicular) from the damper shaft
position.

The minimum straight duct lengths shown
are the absolute minimum.

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2. Drill a 1¼” hole in the side of the duct work. If

probe is longer than 18 inches, drill a 5/16" hole
directly across from the 1¼” hole (Figure 8).

3. Slide foam gasket onto flow station, and insert

into duct work. Insert the flow station through

the 1¼” hole, and into the 5/16" hole (if

required). On probes 18 inches or longer attach
the nut to the threaded end of the flow station
(5/16" hole end).

4. Rotate the flow station until the air flow indicator

arrow matches the correct direction of air flow.

5. Screw the flow station into place with sheet metal

screws (screws not provided by TSI). On 18 inch
and longer flow stations tighten the 5/16” nut.
The finished installation should look like
Figure 8.

Figure 7: Flow Station Mounting Location

Figure 8: Flow Station Hole Location

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6. Verify that the jumpers on the pressure

transducer are installed correctly, per Figure 9.
The default pressure transducer output range is
0 to 0.5 in H2O.

7. Mount the pressure transducer within 10 feet of

the flow station. The transducer must be
mounted on a wall in the correct position per
Figure 10 (screws not provided).

WARNING: DO NOT mount pressure
transducer to ceiling, duct work or vibrating
surfaces. Preferred mounting location is on the
wall nearest the flow station.

8. Run two ¼” pneumatic lines (20’ included)

between flow station and pressure transducer
and connect.

Pressure

Flow Station Transducer

Total to Hi
Static to Lo

Double check that the pneumatic tubing is
correctly plumbed, firmly seated, and has a
tight fit.

Figure 9: Pressure Transducer Jumpers

9. Refer to the wiring diagrams for proper wiring

(Figures 12 and 13). The cable is terminated at
the pressure transducer and at the DIM.

Figure 10: Pressure Transducer Mounting

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TSI Damper/Actuator Installation

WARNING: Building prints normally determine damper location and mounting configuration. They

supersede the guidelines below.

1. The actuators are shipped mounted to the damper. No adjustments are needed prior to mounting

the assembly.

2. The damper must be installed with the damper shaft parallel to the ground (Figure 12).

3. Slip-fit dampers mount INSIDE the ductwork. Flanged dampers bolt to the duct work. No ductwork can be

inside of dampers or interfere with damper rotation.

4. Rivet slip-fit damper to ductwork to ensure damper rotates correctly. Alternate: Use 1-inch or shorter

screws. Make sure screws DO NOT interfere with damper blade rotation; damper rotates outside of
damper sleeve. Bolt flanged dampers securely to ductwork but DO NOT “force” damper to fit
(deforms damper).

5. Pneumatic version require installing a:

 ¼-inch pneumatic line between E/P and actuator (motor).
 20 PSI (30 PSI maximum) ¼-inch pneumatic line to the E/P.

6. Refer to the wiring diagrams for proper wiring (Figures 12 and 13). The cable is terminated at the

damper/actuator and at the DIM.

Figure 11: Proper Damper Mounting

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WARNING: Controller must be wired exactly as wire diagram shows. Making modifications

to the wiring may severely damage the unit.

Figure 12: Diagram – Electric Actuator Version

-5-

WARNING: Controller must be wired exactly as wire diagram shows. Making modifications

to the wiring may severely damage the unit.

Figure 13: Wiring Diagram – Pneumatic Actuator Version

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Figure 14: Transformer Installation

WARNING:

Make sure no power is applied until all
wiring is complete.

Follow all applicable electrical codes,
and have qualified personnel install
the transformer.

NOTE: 115 Volt, single phase, 60 Hertz
power source is required to power the
800420 transformer. If TSI Transformer is
not installed, a regulated 24 Volt, single
phase, 60 Hertz power source is required
to power the controller.

Transformer Installation

Transformers are provided for the DIM/AOC, each damper/actuator, and each flow station (TSI). Thermostat
manufacturer provides transformer to power thermostat.

WARNING: Each damper/actuator and flow station has a separate transformer that must be installed.

DO NOT wire more than one device per transformer.

1. Mount a standard 4" x 4" x 1½" electrical box at a convenient location within 20 feet (transformer cable is

25’ long) of the device being installed; Adaptive Offset Controller, damper/actuator, or flow station. Each
device must have a separate transformer. DO NOT INSTALL MULTIPLE DEVICES ON ONE
TRANSFORMER.

2. Run 115 Volt, single phase, 60 hertz line voltage (115 VAC) to transformer electrical box. Follow all

applicable electrical codes.

3. Connect 115 VAC line voltage HOT wire to BLACK wire on transformer and NEUTRAL wire to WHITE wire

on transformer (Figure 14).

4. Connect the RED wire on 800414 transformer cable to either of the YELLOW wires on the transformer and

the BLACK wire to the remaining YELLOW wire.

5. Screw the transformer to the electrical box.

6. Run transformer cable from the transformer electrical box to the device. Have at least 8 inches of extra

cable at the device before trimming cable to length. Wire devices per Figures 12 and 13.

If you need assistance installing the system, call TSI Customer Service at 651-490-2811 or 800-874-2811.

TSI Incorporated – Visit our website www.tsi.com for more information.

P/N 1980287 Rev. F ©2017 TSI Incorporated Printed in U.S.A.