KMC CONTROLS BAC-7302C Advanced Applications Controller User Guide

Installation and Operation Guide

BAC-7302C Advanced Applications Controller

BAC-7302 and BAC-7302C
Advanced Applications Controller

Important notices

©2013, KMC Controls, Inc.
WinControl XL Plus, NetSensor, and the KMC logo are registered trademarks of KMC Controls, Inc.
BACstage and TotalControl are trademarks of KMC Controls, Inc.
MS/TP automatic MAC addressing is protected under United States Patent Number 7,987,257.
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
P. O . B o x 4 9 7
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

About the BAC-7302

This section provides a general description of the KMC Controls BAC-7302 controller. It also introduces safety information. Review this material before installing or operating the controller.
The BAC-7302 is a native BACnet, fully programmable controller designed for roof top units. Use this versatile controller in stand-alone environments or networked to other BACnet devices. As part of a complete facilities management system, the BAC-7302 controller provides precise monitoring and control of connected points.
◆ BACnet MS/TP compliant
◆ Automatically assigns the MAC address and the device instance
◆ Triac outputs for fan control, two-stage heating and two-stage cooling
◆ Supplied with programming sequences for roof top units
◆ Easy to install, simple to configure, and intuitive to program
◆ Controls room temperature, humidity, fans, monitors refrigeration, lighting, and other building automation functions.

Specifications
Inputs

Accumulators limited to three in one controller.
Standard units of measure.
NetSensor compatible
Overvoltage input protection
Pull–up resistors| Switch select none or 10kW.
Connector| Removable screw terminal block, wire size 14–22 AWG
Conversion| 10–bit analog–to–digital conversion
Pulse Counting| Up to 16 Hz
Input range| 0–5 volts DC
NetSensor| Compatible with models KMD–1161 and KMD–1181.
Outputs, Universal| 1
---|---
 Key features| Output short protection
Programmable as an analog or binary object.
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 range
Output current| 100 mA per output
Outputs, Single-stage triac| 1
---|---
Key features| Optically isolated triac output.
Programmable a binary object.
Connector| Removable screw terminal block Wire size 14-22 AWG
Output range| Maximum switching 30 volts AC at 1 ampere
Outputs, Dual-stage triac| 2
---|---
Key features| Optically isolated triac output.
Programmable as binary object.
Connector| Removable screw terminal block
Wire size 14-22 AWG
Output range| Maximum switching 30 volts AC at 1 ampere

Communications

BACnet MS/TP| EIA–485 operating at rates up to 76.8 kilobaud.
Automatic baud detection.
Automatically assigns MAC addresses and device instance numbers.
Removable screw terminal block.
Wire size 14–22 AWG
---|---
NetSensor| Compatible with models KMD–1161 and KMD–1181,
Connects through RJ–12 connector.

Programmable features

See PIC statement for supported BACnet objects

Schedules

Alarms and events

Intrinsic reporting| Supported for input, output, value, accumulator, trend and loop objects.
---|---
Notification class objects| 8
MemoryPrograms and program parameters are stored in nonvolatile memory.
Auto restart on power failure
Application programs| KMC Controls supplies the BAC-7302 with programming sequences for roof top units:
◆ Roof top operation based on occupancy, night setback, proportional hot and chilled water valve control.
◆ Economizer operation.
◆ Freeze protection.
---|---
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
---|---

Environmental limits

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| 8.2 ounces (112 grams)
Case material| Flame retardant green and black plastic

Models

Accessories
Dimensions

Table 1-1 BAC-7302 Dimensions

Power transformer

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
Danger represents the most severe hazard alert. Bodily harm or death will occur if danger guidelines are not followed.
Warning
Warning represents hazards that could result in severe injury or death.
Caution
Caution indicates potential personal injury or equipment or property damage if instructions are not followed.
Note
Notes provide additional information that is important.
Detail
Provides programing tips and shortcuts that may save time.

Installing the controller

This section provides a brief overview of the BAC-7302 and the BAC-7302C Direct Digital Controllers. Review this material before you attempt to install the controller.

Mounting
Mount the controller inside of a metal enclosure. KMC Controls recommends using a UL-approved Enclosed Energy Management Equipment Panel such as a KMC model HCO–1034, HCO–1035 or HCO–1036. Insert #6 hardware through the four mounting  holes on the top and bottom of the controller to securely fasten it to a flat surface. See Dimensions on page 6 for mounting hole locations and dimensions. To maintain RF emission specifications, use either shielded connecting cables or enclose all cables in conduit.
Connecting inputs
The BAC-7302 controller has four universal inputs. Each input can be configured to receive either analog or digital signals. By using the optional pull-up resistors, either passive or active devices may be connected to the inputs.
Note
KMC supplied Control Basic programs assign input 1 (I1) to the space temperature sensor input. If the KMC programs are not in used or are modified, input 1 is available for other use. Inputs 2 and 3 are not assigned by KMC programs and are available as needed.
Pull–up resistors
For passive input signals, such as thermistors or switch contacts, use a pull- up resistor. For KMC thermistors and most other applications set the switch to the On position. See Illustration 2-1 for the pull-up switch location.

Illustration 2-1 Pull-up resistors and input terminals

Connecting outputs

4–20 mA inputs
To use a 4–20 current loop input, connect a 250 ohm resistor from an input to ground. The resistor will convert the current input to a voltage which can be read by the controller analog-to-digital converter. Set the pull-up switch to the Off position.
Ground terminals
Input ground terminals are located next to the input terminals. Up to two wires, size 14–22 AWG, can be clamped into each ground terminal.
If more than two wires must be joined at a common point, use an external terminal strip to accommodate the additional wires.
Pulse inputs
Connect pulse inputs under the following conditions:
◆ If the pulse input is a passive input such as switch contacts, then place the input pull-up in the On position.
◆ If the pulse is an active voltage (up to a maximum of +5 volts DC ), then place the input pull-up jumper in the Off position.

Connecting outputs
The BAC-7302 includes one single-stage triac, two-three stage triacs and one universal output. All triacs are rated for 24 volt, 1 ampere loads, switch on zero crossing and are optically isolated.

Illustration 2-2 Output terminals

Caution
When connecting loads to triacs, use only the terminal marked RTN associated with each triac for the 24-volt ciruit.
Output 1 This output a single triac is designed to switch a 24-volt AC fan motor starter circuit.
Output 2 Typically programmed with a PID loop object to control two- stage heating. Triac 2A turns on when the programmed output is above 40% and turns off below 30%. Triac 2B turns on when the programmed output is above 80% and turns off below 70%.
Output 3 Typically programmed with a PID loop object to control two-stage cooling. Triac 3A turns on when the programmed output is above 40% and off below 30%. Triac 3B turns on when the programmed output is above 80% and turns off below 70%.
Output 4 This output is a universal output that can be programmed as either an analog or digital object.

Connecting to a NetSensor
The Network RJ–12 connector provides a connection port to a NetSensor model KMD–1161 or KMD–1181. 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.

Illustration 2-3 Connection to a NetSensor

Connecting to an 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.
◆ Use 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 seven repeaters per MS/TP network.
◆ Place a KMD–5567 surge surpressor in the cable where it exits a building.

Connecting to an MS/TP network
See Application Note AN0404A, Planning BACnet Networks for addional information about installing controllers.

Illustration 2-4 MS/TP network wiring

Note
The BAC-7302 EIA–485 terminals are labeled -A, +B and S. The S terminal 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 ground.
End of line termination switches
The controllers on the physical ends of the EIA-485 wiring segment must have endof-line termination installed for proper network operation. Set the end-of- line termination to On using the EOL switches.

Illustration 2-5 End of line termination

Illustration 2-6 shows the position of the BAC-7001 End-of-Line switches associated with the EIA–485 inputs.

Illustration 2-6 Location of EOL switch

Connecting power
The controllers require an external, 24 volt, AC power source. Use the following guidelines when choosing and wiring transformers.
◆ Use a KMC Controls Class–2 transformer of the appropriate size to supply power to the controllers. KMC Controls recommends powering only one controller from each transformer.
◆ When installing a controller in a system with other controllers, you may power multiple controllers with a single transformer as long as the total power drawn from the transformer does not exceed its rating and phasing is correct.
◆ If several controllers are mounted in the same cabinet, you can share a transformer between them provided the transformer does not exceed 100 VA or other regulatory requirements.
◆ Do not run 24 volt, AC power from within an enclosure to external controllers.
Connect the 24 volt AC power supply to the power terminal block on the lower right side of the controller near the power jumper. Connect the ground side of the transformer to the – or GND terminal and the AC phase to the ~ (phase) terminal.
Power is applied to the controller when the transformer is plugged in and the power jumper is in place.

Illustration 2-7 Power terminal and jumper

Programming
Network configuration
For more information on installing, configuring, and programming HVAC system controllers, see the following documents available on the KMC Controls web site:
◆ BACstage User’s Guide to Installation and Getting Started (902-019-62)
◆ BAC-5000 Reference Guide (902019-63)
◆ TotalControl Reference Guide
◆ Application Note AN0404A Planning BACnet Networks.
◆ MS/TP Automatic MAC Addressing Installation Instructions

Supplied applications programming
Refer to the KMC Digital Applications Manual for information on using the applications programs included with the controller.

Operating the controller

This section provides a brief overview of the BAC-7302 and the BAC-7302C Direct Digital Controllers. Review this material before you attempt to install the controller.
Operation
Once configured, programmed and powered up, the controller requires very little user intervention.
Controls and Indicators
The following topics describe the controls and indicators found on the controller.
Additional information for automatic addressing functions are described in the guide MS/TP Automatic MAC Addressing Installation Instructions that is available from the KMC Controls web site.

Illustration 3-1 Controls and indicators

Network disconnect switch
The network disconnect switch is located on the left side of the controller. Use this switch to enable or disable the MS/TP network connection. When the switch is ON the controller can communicate on the network; when it is OFF, the controller is isolated from the network.
Alternately, you may remove the isolation bulbs to isolate the controller from the network.

Controls and Indicators
Ready LED
The green Ready LED indicates the state of the controller. This includes automatic addressing functions that are fully described in the guide MS/TP Addressing For BACnet Controllers.
Power up During controller initialization, the Ready LED is continuously illuminated for 5 to 20 seconds. Once initialization is complete, the Ready LED begins flashing to indicate normal operation.
Normal operation During normal operation, the Ready LED flashes a repeating pattern of one second on and then one second off.
Restart button acknowledge The restart button includes several functions for automatic addressing that are acknowledged with the Ready LED.
When the restart button is pressed, the Ready LED illuminates continuously until either of the following take place:

• The restart button is released.
• The restart button time-out period is reached and a restart operation is complete. Restart button operations are listed in the following table.

Table 3-1 Ready LED patterns for restart button operations

The controller is set as an automatic addressing anchor. The MAC in the controller is set to 3| A rapid repeating pattern of a short flash followed by a short pause.
The controller has sent the automatic addressing lock command to the network| Two short flashes followed by a long pause. The pattern repeats until the restart button is released.
No restart operation| Ready LED remains unlit until the restart button is released.

Communications (Com) LED
The yellow Communications LED indicates how the controller is communicating with other controllers on the network.
Sole master Repeating pattern of a long flash and a short pause that repeats once a second. It indicates that the controller has either generated the token or is a sole MS/ TP master and has yet to establish communications with other MS/TP devices.
Token passing A short flash each time the token is passed. The frequency of the flash is an indication of how often the device receives the token.
Nomad patterns There are three Com LED patterns that indicate that the controller is an automatic addressing nomad controller that is receiving valid MS/TP traffic.

Table 3-2 Automatic addressing nomad patterns

Error conditions for the LEDs
The two network isolation bulbs, located next to the network switch, serve three functions:
◆ Removing the bulbs opens the EIA-485 circuit and isolates the controller from the network.
◆ If one or both bulbs are lit, it indicates the network is improperly phased. This means that the ground potential of the controller is not the same as other controllers on the network.
◆ If the voltage or current on the network exceeds safe levels, the bulbs operate as fuses and may protect the controller from damage.

Isolation bulbs
The two network isolation bulbs, located next to the network switch, serve three functions:
◆ Removing the bulbs opens the EIA-485 circuit and isolates the controller from the network.
◆ If one or both bulbs are lit, it indicates the network is improperly phased. This means that the ground potential of the controller is not the same as other controllers on the network.
◆ If the voltage or current on the network exceeds safe levels, the bulbs operate as fuses and may protect the controller from damage.

Restoring factory settings
If the controller appears to be operating incorrectly, or is not responding to commands, you may need to reset or restart the controller. To perform a reset or restart, remove the cover to expose the red restart push-button and then use one of the following procedures.
To perform a reset or restart, locate the red restart push-button and then—in order—use one of the following procedures.

1. A warm start is the option least disruptive to the network and should be tried first.
2. If problems persist, then try a cold start.
3. If the problems continues, restoring the controller to factory settings may be required.

Caution
Read all of the information in this section before proceeding!
Note
Momentarily pushing the red reset button while the controller remains powered will have no effect on the controller.
Performing a warm start
A warm start changes the controller as follows:
◆ Restarts the controller’s Control Basic programs.
◆ Leaves object values, configuration, and programming intact.

Caution
In the unlikely event that the checksum test in RAM fails during the warm start, the controller will automatically perform a cold start.
During a cold start, controller outputs may abruptly turn connected equipment on and off. To prevent equipment damage, turn connected equipment off or temporarily remove the output terminal blocks from the controller before performing a warm start.
Do either of the following to perform a warm start:
◆ Reinitialize the controller with either BACstage or TotalControl Design Studio.
◆ Remove the power jumper for a few seconds and then replace it.

Performing a cold start
Performing a cold start changes the controller as follows:
◆ Restarts the controller programs.
◆ Returns all object states to their initial factory settings until the controller programs update them.
◆ Leaves configuration and programming intact.

Caution
Returning object values to their relinquished defaults during a cold start may abruptly turn connected equipment on or off. To prevent equipment damage, turn connected equipment off or temporarily remove the output terminal blocks from the controller before performing a warm start.
To perform a cold start:

1. While the controller is powered, press and hold the restart button.
2. Remove the power jumper.
3. Release the red button before replacing the power jumper.

Note
A cold start performed by this method is the same as performing a cold start with BACstage or from TotalControl Design Studio.

Restoring to factory settings
Restoring a controller to factory settings changes the controller as follows:
◆ Removes all programming.
◆ Removes all configuration settings.
◆ Restores the controller to factory default settings.

Caution
Resetting the controller erases all configuration and programming. After resetting to factory settings, you must configure and program the controller to establish normal communications and operation.
To reset the controller to factory settings.

1. If possible, use BACstage or TotalControl Design Studio to backup the controller.
2. Remove the power jumper.
3. Press and hold the red restart button.
4. Replace the power jumper while continuing to hold the restart button.
5. Restore configuration and programming with BACstage or TotalControl Design Studio.

References

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