KMC CONTROLS BAC-5900 Series BACnet Purpose Controller Installation Guide

KMC CONTROLS BAC-5900 Series BACnet Purpose Controller

BAC-5900 Series Controller

The KMC Conquest BAC-5900 Series BACnet General Purpose Controller is designed to control and monitor HVAC systems. It can be mounted either on a flat surface or on a 35 mm DIN rail and comes with color-coded terminal blocks for easy wiring.

Product Mount Controller

On a Flat Surface

1. Position the controller on a flat surface so that the color-coded terminal blocks are easy to access for wiring after the controller is mounted. The black terminals are for power, the green terminals are for inputs and outputs, and the gray terminals are for communication.
2. Screw a #6 sheet metal screw through each corner of the controller.

On a DIN Rail

1. Position the DIN rail so that the color-coded terminal blocks are easy to access for wiring after the controller is mounted.
2. Pull out the DIN latch until it clicks once.
3. Position the controller so that the top four tabs of the back channel rest on the DIN rail.
4. Lower the controller against the DIN rail.
5. Push in the DIN latch to engage the rail.

Product Connect Sensors and Equipment

1. Plug an Ethernet patch cable connected t o an STE-9000 Series or STE-6010/6014/6017 sensor into the (yellow) ROOM SENSOR port of the controller. The Ethernet patch cable should be a maximum of 150 feet (45 meters).
2. Verify that the controller is not connected to power.
3. Wire any additional sensors to the green (input) terminals. No more than two 16 AWG wires can be joined at a common point.
4. Connect equipment to the green (output) terminals. Do NOT connect 24 VAC to any output without first installing an HPO-6701, HPO-6703, or HPO6705 override board first.

Note that the digital STE-9000 Series NetSensor can be used for configuring the controller. Once the controller has been configured, an STE-6010, STE-6014, or STE-6017 analog sensor can be connected to the controller in place of the NetSensor.

For more information on wiring, refer to the Sample (BAC-5901) Wiring section on page 8 and the BAC-5900 series videos on the KMC Conquest Controller Wiring playlist.

INTRODUCTION

Complete the following steps to install a KMC Conquest BAC-5900 Series BACnet General Purpose Controller. For controller specifications, see the data sheet at kmccontrols.com. For additional information, see the KMC Conquest Controller Application Guide.

MOUNT CONTROLLER

• NOTE: Mount the controller inside a metal enclosure for RF shielding and physical protection.
• NOTE: To mount the controller with screws on a flat surface, complete the steps in On a Flat Surface on page 1. Or to mount the controller on a 35 mm DIN rail (such as integrated in an HCO-1103 enclosure), complete the steps in On a DIN Rail on page 1.

On a Flat Surface

1. Position the controller on a flat surface so that the color-coded terminal blocks 1 are easy to access for wiring after the controller is mounted.
   NOTE: The black terminals are for power. The green terminals are for inputs and outputs. The gray terminals are for communication.

2. Screw a #6 sheet metal screw through each corner 2 of the controller.

On a DIN Rail

1. Position the DIN rail 3 so that the color-coded terminal blocks are easy to access for wiring after the controller is mounted.
2. Pull out the DIN latch 4 until it clicks once.
3. Position the controller so that the top four tabs 5 of the back channel rest on the DIN rail.
4. Lower the controller against the DIN rail.
5. Push in the DIN latch 6 to engage the rail.
   NOTE: To remove the controller, pull the DIN latch until it clicks once and lift the controller off the DIN rail.

CONNECT SENSORS AND EQUIPMENT

• NOTE: A digital STE-9000 Series NetSensor can be used for configuring the controller (see Configure/Program the Controller on page 7). After the controller has been configured, 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-5901) Wiring on page 8 for more information.

1. Plug an Ethernet patch cable 7 connected to an STE-9000 Series or STE-6010/6014/6017 sensor into the (yellow) ROOM SENSOR port 8 of the controller.
   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.

2. Verify the controller is not connected to power.

3. Wire any additional sensors to the green (input) terminal blocks 9 . See Sample (BAC-5901) Wiring on page 8.
   NOTE: Wire sizes 12–24 AWG can be clamped together into each terminal.
   NOTE: No more than two 16 AWG wires can be joined at a common point .

4. Connect equipment to the green (output) terminals 10 . See Sample (BAC-5901) Wiring on page 8 and BAC-5900 series videos on the KMC Conquest Controller Wiring playlist.

CAUTION
Do NOT connect 24 VAC to any output without first installing an HPO-6701, HPO-6703, or HPO- 6705 override board first!

INSTALL (OPTIONAL) OVERRIDE BOARDS

NOTE: Install output override boards for enhanced output options, such as manual control, using large relays, or for devices that cannot be powered directly from a standard output.

1. Verify the controller is not connected to power.
   CAUTION
   Connecting 24 VAC or other signals that exceed the operation specifications of the controller before an override board is installed will damage the controller.

2. Open the plastic cover 11 .

3. Remove the jumper 12 from the slot in which the override board will be installed.
   NOTE: Each of the eight override slots ships from KMC with a jumper installed on the two pins closest to the output terminal blocks. Only remove a jumper if an override board will be installed.

4. Install the override board in the slot in which the jumper was removed 13 .
   NOTE: Position the board with the selection switch 14 towards the top of the controller.

5. Close the plastic cover.

6. Move the A-O-H selection switch 15 on the override board to the appropriate position.
   NOTE:
   A = Automatic (Controller Operated)
   O = Off
   H = Hand (On)
   NOTE: For more information, see the HPO-6700 Series installation guide and the HPO- 6700 series videos in the KMC Conquest Controller Wiring playlist.

7. Wire the output device to the corresponding green (output) terminal block 16 of the override board.
   NOTE: HPO-6701 triac and HPO-6703/6705 relay board circuits use the Switched Common SC terminal—not the Ground Common GND terminal.
   NOTE: HPO-6701 triac outputs are for 24 VAC only.

CONNECT (OPT.) EXPANSION MODULES

NOTE: Up to four CAN-5901 I/O expansion modules can be connected in series (daisy-chained) to a BAC-5900 series controller to add additional inputs and outputs.

1. Wire the gray EIO (Expansion Input Output) terminal block 17 of the BAC-5900 series controller to the gray EIO terminal block of the CAN-5901.
   NOTE: See the CAN-5901 I/O Expansion Module Installation Guide for details.

CONNECT (OPT.) ETHERNET NETWORK

1. For a BAC-5901CE, connect an Ethernet patch cable 7 to the 10/100 ETHERNET port 18 .

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.

• NOTE: The Ethernet patch cable should be T568B Category 5 or better and a maximum of 328 feet (100 meters) between devices.
• NOTE: Before May 2016, BAC-xxxxCE models had a single Ethernet port. They now have dual Ethernet ports 18 , enabling daisy-chaining of controllers. See the Daisy-Chaining Conquest Ethernet Controllers Technical Bulletin for more information.
• NOTE: On newer models, the Room Sensor port is yellow 8 instead of black to help differentiate it from the black Ethernet ports.

CONNECT (OPTIONAL) MS/TP NETWORK

1. For a BAC-5901C, connect the network to the gray BACnet MS/TP terminal block 19 .
   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.
   • C. Connect the shields of the cable together at each device using a wire nut or the S terminal on KMC controllers.
     NOTE: For more information, see Sample (BAC- 5901) Wiring on page 8 and the BAC- 5900 series videos in the KMC Conquest Controller Wiring playlist.

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, see Planning BACnet Networks (Application Note AN0404A).

SELECT END OF LINES (EOL)

NOTE: EOL switches are shipped in the OFF position.

1. If the controller is at either end of a BACnet MS/TP network (only one wire under each terminal), turn that EOL switch 20 to ON.
2. If the controller is at the end of an EIO (Expansion Input Output) network, turn that EOL switch 21 to ON.

CONNECT POWER

NOTE: Follow all local regulations and wiring codes.

1. Connect a 24 VAC, Class-2 transformer to the black power terminal block 22 of the controller.
   • A. Connect the neutral side of the transformer to the controller’s common terminal ⊥ 23 .
   • B. Connect the AC phase side of the transformer to the controller’s phase terminal ∼ 24 .

• NOTE: Connect only one controller to each 24 VAC, Class-2 transformer with 12–24 AWG copper wire.
• NOTE: Use either shielded connecting cables or enclose all cables in conduit to maintain RF emissions specifications.
• NOTE: To use DC power supply instead of AC, see the Power (Controller) Connections section of the KMC Conquest Controller Application Guide.
• NOTE: For more information, see Sample (BAC- 5901) Wiring on page 8 and the BAC- 5900 series videos in the KMC Conquest Controller Wiring playlist.

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 25
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 26

• 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 (EIO) COMM LED 27
The Expansion Input Output (EIO) status LED indicates EIO network communication with one or more CAN-5901 expansion modules. After controller power-up or restart, the LED flickers as it receives and passes the token:

• The EIO LED flashes when the controller is communicating with the EIO network
• The EIO LED remains OFF when the (powered) controller is not communicating with the EIO network. Check the power and EIO network connections.

NOTE: See the CAN-5901 I/O Expansion Module Installation Guide for more information.

Green ETHERNET LED 28
The Ethernet status LEDs indicate network connection and communication speed.

• The green Ethernet LED is 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.

Amber ETHERNET LED 29

• 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).
  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 MS/TP network isolation bulbs 30 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, fix the wiring. See Connect (Optional) MS/TP Network on page 4.
• If the voltage or current on the network exceeds safe levels, the bulbs blow, opening the circuit. If this happens, fix the problem and replace the bulb assembly.

CONFIGURE/PROGRAM THE CONTROLLER

See the table for the most relevant KMC Controls tool for configuring, programming, and/or creating graphics for the controller. See the tools’ documents or Help systems for more information.
NOTE: After the controller has been configured, 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-5901CE can be configured by connecting an HTML5-compatible web browser to the controller’s default IP address (192.168.1.251). See the Conquest Ethernet Controller Configuration Web Pages Application Guide for more information about the built-in configuration web pages.

Page **Graphics***
|  |  | Conquest Net- Sensor

|  |  | Internal con- figuration web pages in Con- quest Ethernet “E” models**

|  |  | KMC Connect Lite™ (NFC) app***
| |  | KMC Connect™ software
| | | TotalControl™ software

|

|  | KMC Converge™ module for Niagara Work- bench
 |  |

| KMC Converge™ GFX module for Niagara Workbench
*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 firmware can be configured with an HTML5 compatible web browser from pages served from within the controller. For information, see the [Con](https://www.kmccontrols.com/product/BAC-5901CE/) [quest Ethernet Controller Configuration Web](https://www.kmccontrols.com/product/BAC- 5901CE/) [Pages Application Guide**](https://www.kmccontrols.com/product /BAC-5901CE/).

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

****Full configuration and programming of KMC Conquest controllers is supported starting with TotalControl™ ver. 4.0.

SAMPLE (BAC-5901) WIRING

10(General Purpose Applications)

CAUTION: Do NOT connect 24 VAC to the outputs unless an HPO-6701, HPO-6703, or HPO-6705 are installed!

REPLACEMENT PARTS

• 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

1. Black 2 Position
2. Grey 3 Position
3. Green 3 Position
4. Green 4 Position
5. Green 5 Position
6. Green 6 Position

DIN Clips

2. Small
3. Large

NOTE: See the Conquest Selection Guide for more information about replacement parts and accessories.

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.
The KMC logo is a registered trademark of KMC Controls, Inc. All rights reserved.
The KMC Connect Lite™ app for NFC configuration is protected under United States Patent Number 10,006,654. Pat. https://www.kmccontrols.com/patents/

• TEL: 574.831.5250
• FAX: 574.831.5252
• EMAIL: info@kmccontrols.com

© 2022 KMC Controls, Inc.
Specifications and design subject to change without notice

References

• KMC Controls | Building Automation and Control Solutions
• KMC Controls | Building Automation and Control Solutions
• KMC Controls | Building Automation and Control Solutions
• KMC Controls | Building Automation and Control Solutions
• KMC Conquest General Purpose Controllers | KMC Controls
• Controller: General Purpose, BACnet AAC, Clock, MSTP | KMC Controls
• Controller: General Purpose, BACnet AAC, Clock, Ethernet | KMC Controls
• I/O Expansion Module, 8 Universal Inputs, 8 Universal Output
• STE-6000 Series Room Temperature Sensors/Transmitters | KMC Controls
• STE-9000 Series NetSensors | KMC Controls
• NetSensor: Temperature, Occupancy, CO2, White | KMC Controls

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