TSI SureFlow 8681 Adaptive Offset Controller Instruction Manual

: July 30, 2024
: tsi

Table of Contents

TSI SureFlow 8681 Adaptive Offset Controller
Specifications
Product Usage Instructions
FAQ
Overview
Component List
Digital Interface Module Installation
Wiring
Pressure Sensor Installation
Flow Station Installation
Damper/Actuator Installation
Transformer Installation
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References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

TSI SureFlow 8681 Adaptive Offset Controller

Specifications

Product Name : SureFlowTM Adaptive Offset Controller
Model: 8681
Power Requirement : 24 VAC

Product Usage Instructions

Component Installation:
Refer to the provided building prints for the location of dampers, flow stations, and pressure sensor. If no location is defined, follow typical installation locations as shown in the instructions.

Component List:
Ensure you have all the necessary components listed in the manual for installation.

Digital Interface Module Installation:

Select the mounting location for the DIM.
Install a standard double gang electrical box.
Remove screws holding electronics to the base and mount the base to the electrical box.
Refer to wiring diagrams for proper cable connections at the DIM and other devices.
Securely mount the DIM to the base and cover it.

Wiring Instructions:
Ensure that only 24 VAC is connected to any terminal. Do not apply voltage to specific outputs to prevent damage to the unit.

FAQ

What should I do if I mistakenly wire the unit to 110 VAC?
Wiring the unit to 110 VAC will cause serious damage and void the warranty. Please ensure to wire it only to 24 VAC as specified in the manual.
How do I find the mounting location for components?
Refer to building prints provided with the product. If no specific location is defined, follow the typical installation locations shown in the manual.

WARNING
The Model 8681 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 8681 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.

Overview

Figure 1 provides an overview of the various components installed. The order the components are installed is not important. The building prints will define the location of the dampers, flow stations, and pressure sensor. If no location is defined, these instructions show “typical” installation locations.

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 or may not have all components or quantity of components listed below.
Only TSI supplied devices, listed below and on next page, are covered in these installation instructions.
Please refer to the manufacturer’s installation instructions for proper installation of non TSI devices.

Adaptive Offset Controller

Flow Stations (each Unit)

Part Number|

Qty

|

Description

---|---|---
NONE| 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

---|---|---
None| 1| Damper – sized for duct
800420| 1| Transformer
800414| 2| Transformer cable – second cable is for control signal
800370| 1| Electric actuator

Digital Interface Module Installation

Select the mounting location of the Digital Interface Module (DIM). The construction plans normally show the mounting location. If no location is specified, then the unit is typically installed as shown in Figure 1, either in the laboratory or in the hallway.
Install a standard double gang electrical box (4” x 4”).
Slide the DIM cover to the right and remove three screws holding the electronics to the base (Figure 2). Remove base.
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.
Refer to the wiring diagrams for proper wiring (Figure 10 and Figure 11). The cables are terminated both at the DIM, and at the appropriate device.
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.
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.

Remove the connectors from the back of DIM.
Refer to Figure 10 and Figure 11 wiring diagram for pressure sensor, DIM, TSI® Damper/actuator, and TSI® flow station wiring. Refer to Figure 12 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.
Strip 1/4” to 3/8” insulation from the wires. Twist stranded wire to eliminate loose strands.
Insert wire into connector and tighten.
Insert connector into proper receptacle.

Pressure Sensor Installation

NOTE
See the installation instructions for the 800326 pressure sensor.

Flow Station Installation

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 5 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 90o (perpendicular) from the damper shaft position. The minimum straight duct lengths shown are the absolute minimum.
Drill a 1-1/4” hole in the side of the duct work. If probe is longer than 18 inches, drill a 5/16″ hole directly across from the 1-1/4” hole (Figure 5).
Slide foam gasket onto flow station, and insert into duct work. Insert the flow station through the 1-1/4” 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).
Rotate the flow station until the air flow indicator arrow matches the correct direction of air flow.
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 6.
Verify that the jumpers on the pressure transducer are installed correctly, per Figure 7. The default pressure transducer output range is 0 to 0.5 in. H2O.
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 8 (screws not provided).
WARNING
DO NOT mount pressure transducer to ceiling, ductwork or vibrating surfaces. Preferred mounting location is on the wall nearest the flow station.
Run two 1/4” pneumatic lines (20’ included) between flow station and pressure transducer and connect.

Flow Station

| | Pressure Transducer
---|---|---
Total Static| to to| Hi Lo

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

Refer to the wiring diagrams for proper wiring (Figure 10 and Figure 11). The cable is terminated at the pressure transducer and at the DIM.
WARNING
DO NOT mount pressure transducer to ceiling, ductwork or vibrating surfaces. Preferred mounting location is on the wall nearest the flow station.

Damper/Actuator Installation

WARNING
Building prints normally determine damper location and mounting configuration. They supersede the guidelines below.

The actuators are shipped mounted to the damper. No adjustments are needed prior to mounting the assembly.
The damper must be installed with the damper shaft parallel to the ground (Figure 9).
Slip-fit dampers mount INSIDE the duct work. Flanged dampers bolt to the duct work. No ductwork can be inside of dampers, or interfere with damper rotation.
Rivet slip-fit damper to duct work to ensure damper rotates correctly. Alternate: use 1-inch or shorter screws. Make sure screws do not interfere with damper blade rotation; damper blade rotates outside of damper sleeve. Bolt flanged dampers securely to ductwork, but do not “force” damper to fit (deforms damper).
Refer to the wiring diagrams for proper wiring (Figure 10 and Figure 11). The cable is terminated at the damper/actuator and at the DIM.

Transformer Installation

Transformers are provided for the DIM/AOC, each damper/actuator, and each flow station (TSI®).
WARNING
Each damper/actuator and flow station has a separate transformer that must be installed. DO NOT wire more than one device per transformer.

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.

Mount a standard 4″ x 4″ x 1-1/2” 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.
Run 115 volt, single phase, 60 hertz line voltage (115 VAC) to transformer electrical box. Follow all applicable electrical codes.
Connect 115 VAC line voltage HOT wire to BLACK wire on transformer and NEUTRAL wire to WHITE wire on transformer (Figure 12).
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.
Screw the transformer to the electrical box.
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 Figure 10 and Figure 11.
If you need assistance installing the system, call TSI® Customer Service at 651-490-2860 or 1-800-680-1220.