KMC CONTROLS BAC-9000 Series VAV Controller Installation Guide

BAC-9000 Series VAV Controller
Installation Guide

INTRODUCTION

Complete the following steps to install a KMC  Conquest™ BAC-9000 Series VAV ControllerActuator. For controller specifications, see the datasheet at kmccontrols.com. For additional information, see the KMC Conquest Controller Application Guide.
SET DRIVE HUB (45/60°) ROTATION LIMIT
NOTE: When shipped from the factory, the drive hub can rotate 90 degrees. However, you can install rotation limits at 45 or 60 degrees using the included stop screw if required by the VAV box. Complete the steps in this section ONLY IF the VAV damper rotation limit is either 45 or 60 degrees. If the VAV damper rotates 90 degrees, skip this section and go to Mount The controller on page 2 instead.
NOTE: Damper positions for minimum and maximum airflow are set during the balancing procedure at a later stage. See Configure/Program the Controller on page 7.

1. Push and hold the gear release 1 and rotate the drive hub and V-clamp 2 to the left.
   NOTE: The V-clamp nuts 3 should be on top.
   

2. Turn the controller over.

3. Remove the stop screw 4 from the storage location and clean debris from the threads.
   

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

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.

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 7 on the VAV box to fully open the damper.
   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 8 on the side of the controller.

3. Rotate the drive hub and V-clamp 9 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 10 so that the color-coded terminal blocks are easy to access for wiring.
   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 11 to position the damper shaft in the drive hub.
   

6. Center the mounting bushing 12 in the mounting tab 13 .
   

7. Attach the controller to the VAV box with a #8 sheet metal screw through the mounting bushing 12.

8. Evenly tighten the V-clamp nuts 11 on the drive hub to 30–35 in-lb.

CONNECT SENSORS AND EQUIPMENT

NOTE: For more information, see Sample (BAC-9001) Wiring on page 8, Input/ Output Objects/Connections on page
9. See also the BAC-9000 series videos in the KMC Conquest Controller Wiring playlist.
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.

1. Plug an Ethernet patch cable 14 connected to an STE-9xxx or STE-6010/6014/6017 sensor into the controller’s (yellow 22 ) ROOM SENSOR 15 port.
   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 Sensorport! The Room Sensor port powers a NetSensor, and the supplied voltage may damage an Ethernet switch or router
   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 17. See
   CAUTION
   Do NOT connect 24 VAC to the analog connect 24 VAC to the analog outputs (UO3–UO5 and GNDs)!
   NOTE: Use 24 VAC (only) with Triac outputs (BO6–BO9 with SC).
   NOTE: Wire sizes 12–24 AWG can be clamped in each terminal.
   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 airflow sensor to the controller.
NOTE: Only the BAC-9021 controller does not have PRESSURE SENSOR ports. For that model, skip this section.
NOTE: Use 1/4 inch (6.35 mm) FR (Flame Retardant) tubing. Tubing should not be longer than 20 feet (6 meters).

1. Remove the black shipping plugs 16 from the PRESSURE SENSOR ports.
2. Connect the high-pressure tube from the pressure-flow sensor to the HIGH 18 port on the controller.
3. Connect the low-pressure tube from the pressure-flow sensor to the LOW 19 port on the controller.

CONNECT (OPT.) ETHERNET NETWORK

1. For a BAC-9001C E (only), connect an Ethernet patch cable 20 to the 10/100 ETHERNET port.
   **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:** Before May 2016, BAC-9001CE models had a single Ethernet port 20. They now have dual Ethernet ports 21, enabling daisy-chaining of controllers. See the Daisy-Chaining Conquest Ethernet Controllers Technical Bulletin for more information.

NOTE: Also on the newer models, the Room Sensor port is yellow 22 instead of black to help differentiate it from the black Ethernet ports.
NOTE: The Ethernet patch cable should be T568B Category 5 (or better) and a maximum of 328 feet (100 meters) between devices.
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 23.
   NOTE: Use 18 gauge AWG shielded twisted pair cable with the 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 in KMC BACnet controllers.

2. Connect the cable shield to 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).
   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 24 to ON.
   NOTE: For more information, see Sample (BAC-9001) Wiring on page 8 and the BAC-9000 series videos in the KMC Conquest Controller Wiring playlist.
   

CONNECT POWER

NOTE: Follow all local regulations and wiring codes.

1. Connect a 24 VAC, Class-2 transformer to the black power terminal block 25 of the controller.
   A. Connect the neutral side of the transformer to the controller’s common terminal ⊥ ⊥ 26.
   B. Connect the AC phase side of the transformer to the controller’s phase terminal ∼ ∼ 27.
   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 specifications.
   NOTE: For more information, see Sample (BAC-9001) Wiring on page 8 and the BAC-9000 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 remains OFF, check the power and cable connections to the controller.
Green READY LED 28
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 29

• 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 30
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.

Amber ETHERNET LED 31

• 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 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 phrased. 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 5.

• 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.

WATCHDOG JUMPER

The watchdog 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).

CONFIGURE/PROGRAM THE CONTROLLER

See the table (on the next page) for the most relevant KMC Controls tools 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 a STE9000 series digital NetSensor.
NOTE: ABAC-9001CE 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.
NOTE: To configure a VAV controller, enter the correct K factor for the VAV box. Typically, this is supplied by the manufacturer of the VAV unit. If this information is unavailable, use an approximate K factor from the chart in the Appendix: K Factors for VAV section in the KMC Conquest Controller Application Guide.

For instructions on VAV balancing:

• With an STE-9000 series NetSensor, see the VAV Airflow Balancing with an STE-9xx1 section of the KMC Conquest Controller Application Guide.
• With a BAC-5051E Router, see its application and installation guide.
• With KMC Connect or TotalControl, see the Help system for the software.

Graphics*
✓| | | Conquest NetSensor
✓| | | Internal configuration web pages in Conquest Ethernet ‘Es models*
✓| | | KMC Connect Lite- (NFC) app
✓| ✓| | KMC Connect- software
✓| ✓| ✓| TotalControlsoftware
✓| ✓| | KMC Converge module for Niagara Workbench
| | ✓| 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 Conquest Ethernet Controller Configuration Web Pages Application Guide.
Near Field Communication via enabled smartphone 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-9001) WIRING

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

INPUT/OUTPUT OBJECTS/CONNECTIONS

BAC-9001 SINGLE DUCT

Inputs (Objects/Terminals)
All| Space Sensor (on Room Sensor port)
Al2| Space Setpoint Offset (on port)
A13/U13| Discharge Air Temperature
A14/U14| Analog Input #4
A15/U15| Analog Input #5
A16/U16| Analog Input #6
Al7| Primary Duct Pressure (internal sensor)
Al8| Primary Damper Position (internal sensor)
Outputs (Objects/Terminals)
A03/UO3| Analog Heat
A04/U04| Fan Speed
A05/U05| Analog Output #5
B01| Primary Damper CW (internal actuator)
B02| Primary Damper CCW (internal actuator)
B06| Fan
B07| Heating Stage 1
B08| Heating Stage 2
B09| Heating Stage 3

• NOTE ABOUT REHEAT:
  • When staged heating is configured (on MSV3), BO7, BO8, and BO9 activate in sequence.
  • When floating (tri-state) heating is configured, BO7 opens and BO8 closes (BO9 is not used).
  • When time proportional heating is configured, BO7 is the controlling output (BO8 and BO9 are not used).
  • AO3 is always active (and a voltage test on it always reflects the heating PID loop value even when AO3 is not the controlling output). When modulating heating is configured, AO3 is the controlling output (BO7, BO8, and BO9 are not used).
  BAC-9021 PRESSURE DEPENDENT

  Inputs
  All| Space Sensor (on Room Sensor port)
  Al2| Space Setpoint Offset (on port)
  A13/U13| Discharge Air Temperature
  A14/U14| Analog Input #4
  A15/U15| Analog Input #5
  A16/U16| Analog Input #6
  | (No internal pressure sensor in this model)
  Al8| Primary Damper Position (internal sensor)
  Outputs
  A03/UO3| Analog Heat
  A04/U04| Analog Output #4
  A05/U05| Analog Output #5
  B07| Primary Damper CW (internal actuator)
  B02| Primary Damper CCW (internal actuator)
  B06| Binary Output #6
  B07| Heating Stage 1
  B08| Heating Stage 2
  B09| Heating Stage 3

• See NOTE ABOUT REHEAT above.
  BAC-9001 DUAL DUCT

  Inputs
  All| Space Sensor (on Room Sensor port)
  Al2| Space Setpoint Offset (on port)
  A13/U13| Discharge Air Temperature
  A14/U14| Analog Input #4
  A15/U15| Secondary Duct Pressure
  A16/U16| Secondary Damper Position
  Al7| Primary Duct Pressure (internal sensor)
  Al8| Primary Damper Position (internal sensor)
  Outputs
  A03/UO3| Analog Output #3
  A04/U04| Analog Output #4
  A05/U05| Analog Output #5
  B01| Primary Damper CW (internal actuator)
  B02| Primary Damper CCW (internal actuator)
  B06| Binary Output #6
  B07| Secondary Damper CW
  B08| Secondary Damper CCW
  B09| Binary Output #9

NOTE: For more information, see Sample
(BAC-9001) Wiring on page 8.
NOTE: Universal Input (UIx) terminal = Analog Input (AIx) object. Universal Output (UOx) terminal = Analog Output (AOx) object.
NOTE: Universal (analog) inputs and outputs can be configured to emulate binary (on/off or voltage/no-voltage) objects. They are used with GND terminals.
NOTE: Binary Output (BOx) terminals are triacs and are used with SC terminals instead of GND terminals.

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

1. Small
2. Large

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.
TEL: 574.831.5250
FAX: 574.831.5252
EMAIL: info@kmccontrols.com
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
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• KMC Conquest VAV Controllers | KMC Controls
• Controller: VAV, PI, BACnet AAC, 40 in-lbs, 90 sec., MSTP | KMC Controls
• Controller: VAV, PI, BACnet AAC, 40 in-lbs, 90 sec, Clock
• Browse all of our KMC products today and find the right fit for you!
• NetSensor: Temperature, Almond | KMC Controls
• NetSensor: Temperature, Humidity, Occupancy, CO2, White | KMC Controls

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