BAC-9000(A) Series VAV Controller

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Specifications

• Product: BAC-9000(A) Series VAV Controller
• Manufacturer: KMC Controls
• Model: BAC-9000(A)

Product Usage Instructions

Installation Guide

1. Push and hold the gear release 1 and rotate the drive hub and
   V-clamp 2 to the left.

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 or 45 stop hole
   position.

5. Tighten the screw until the screw head touches the plastic in
   the bottom of the recess.

6. Manually rotate the damper shaft on the VAV box to fully open
   the damper.

7. Push and hold the gear disengagement lever on the side of the
   controller.

8. Rotate the drive hub and V-clamp in the same direction that
   opened the damper.

9. Position the controller over the damper shaft so that the
   color-coded terminal blocks are easy to access for wiring.

10. Finger-tighten the V-clamp nuts to position the damper shaft in
    the drive hub.

11. Center the mounting bushing in the mounting tab.

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

FAQ

Q: Can I use a digital NetSensor for configuring the

controller?

A: Yes, a digital STE-9000 Series NetSensor can be used for
configuring the controller. After configuration, an analog sensor
like STE-6010, STE-6014, or STE-6017 can be connected in place of
the NetSensor. Refer to the relevant installation guide for
details.

Q: What precautions should be taken with Conquest E

models?

A: Do NOT plug an Ethernet communication cable into the Room
Sensor port on Conquest E models as it may damage Ethernet
equipment. The Room Sensor port is meant for powering a NetSensor
only.

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BAC-9000(A) Series VAV Controller
Installation Guide

CONTENTS
Introduction ………………………………………. 1 Set Drive Hub (45/60°) Rotation Limit………… 1 Mount Controller…………………………………. 2 Connect Sensors and Equipment ……………… 3 Connect (Optional) Pressure Sensor………….. 4 Connect (Opt.) Ethernet Network ……………… 4 Connect (Optional) MS/TP Network…………… 5 Connect Power …………………………………… 5 Power and Communication Status…………….. 6 MS/TP Network Isolation Bulbs ……………….. 6 Watch Dog Jumper ………………………………. 6 Configure/Program the Controller…………….. 7 Sample (BAC-9001A) Wiring…………………… 8 Input/Output Objects/Connections ……………. 9 Replacement Parts………………………………10 Important Notices ……………………………….10
INTRODUCTION
Complete the following steps to install a KMC ConquestTM BAC-9000(A) Series VAV Controller-Actuator. For controller specifications, see the data sheet 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 rotatation 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 Controller on page 2 instead.
NOTE: Damper positions for minimum and maximum air flow 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.

2

1

NOTE: The V-clamp nuts 3 should be on top. 3

2. Turn the controller over. 3. Remove the stop screw 4 from the storage
location and clean debris from the threads.
4

KMC Controls, 19476 Industrial Drive, New Paris, IN 46553 / 877.444.5622 / Fax: 574.831.5252 / www.kmccontrols.com

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

box to fully open the damper. 7

6
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’s 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 3/8­5/8 inch (9.5­16 mm) round or 3/8­7/16 inch (99.5­11 mm) square damper shaft with a minimum length of 2 inches (51 mm).
1. Manually rotate the damper shaft 7 on the VAV

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.

9

8

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.

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controller’s (yellow 22 ) ROOM SENSOR 15 port.

10

14

11

6. Center the mounting bushing 12 in the mounting tab 13 .
12 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 30­35 in-lb.

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.
16
15

CONNECT SENSORS AND EQUIPMENT
NOTE: For more information, see Sample (BAC9001A) Wiring on page 8 and 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
BAC-9000 Series Controller Installation Guide

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 Sample (BAC-9001A) Wiring on page 8.
CAUTION
Do NOT connect 24 VAC to the analog outputs (UO3­UO5 and GNDs)!
NOTE: Use 24 VAC (only) with triac outputs (BO6­ BO9 with SC).

3

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NOTE: Wire sizes 12­24 AWG can be clamped in each terminal.
NOTE: No more than two (16 AWG) wires can be joined at a common point.
17

18

19

CONNECT (OPTIONAL) PRESSURE SENSOR
NOTE: Complete the steps in this section to connect an air flow 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-9001(A)CE (only), connect an Ethernet patch cable 20 to the 10/100 ETHERNET port 21 .
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 daisychaining of controllers. See the DaisyChaining Conquest Ethernet Controllers Technical Bulletin for more information.
20

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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.

22

21

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 maximum capacitance of 51 picofarads per foot (0.3 meters) for all network wiring (Belden cable

82760 or equivalent).

23

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 (BAC9001A) Wiring on page 8 and the BAC9000 series videos in the KMC Conquest Controller Wiring playlist.
24
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 .

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 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).

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26

25

27

NOTE: Connect only one controller to each transformer with 12­24 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 (BAC9001A) Wiring on page 8 and the BAC9000 series videos in the KMC Conquest Controller Wiring playlist.
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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 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).

29
28
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.

30

31

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
32
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 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 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.
WATCH DOG JUMPER The watch dog 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).

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33
CONFIGURE/PROGRAM THE CONTROLLER
See the table (in the column to the right) 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 an STE-9000 series digital NetSensor.
NOTE: A BAC-9001(A)CE 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 of the software.

SETUP PROCESS
Configu- Programming Web Page ration (Control Basic) Graphics*

KMC CONTROLS
TOOL

Conquest NetSensor

Internal con-

figuration web

pages in Con-

quest Ethernet

“E” models**

KMC Connect

LiteTM (NFC)

app***

KMC ConnectTM software

TotalControlTM

software

KMC ConvergeTM module for Niagara Workbench

KMC Converge

GFX module for Niagara Work-

bench

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 quest Ethernet Controller Configuration Web Pages Application Guide.
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.

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SAMPLE (BAC-9001A) WIRING

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

BAC-9001/9001CE Controller

NOTE: For MS/TP models, turn the End Of Line switch ON at both physical ends of the MS/TP network. Connect the cable shield to earth ground at only one point.

NOTE: For more wiring examples, see the wiring diagrams that are part of the application library in KMC Connect, Converge, or TotalControl.

COM RDY

­
SHLD BLK RED SHLD BLK RED

From Previous Controller

To Next Controller

STE-9521

-A +B S
ROOM SENSOR
10/100 ETHERNET

STE-6010-10

To Ethernet

NOTE: Connect the STE-9xxx (or STE-6010/6014/6017 with no ventilation control) sensor to the Room Sensor port using a max. of 150 feet of Ethernet patch cable.
NOTE: For Ethernet models, connect the controller to the network with a standard Ethernet patch cord.
NOTE: Analog inputs accept 1K or 10K sensors, 0­12 VDC, or 4­20 mA.

(Optional)
DAT STE-1405 10K Ohm
Type 3 Thermistor

UI3 GND UI4 UI5 GND UI6 UO3 GND UO4 GND UO5 BO6 BO7 SC BO8 BO9
~

ON OFF EOL
BACnet MS/TP

CONNECTIONS (SAMPLE)

PRESSURE SENSOR

INPUTS

HIGH

H

UI3 = DAT SENSOR

1/4″ (6.35) FR tubing

ROOM SENSOR

LOW

to flow sensor L

OUTPUTS (Binary/Triac) BO6 = FAN ENABLE

BO7 = OPEN VALVE

BO8 = CLOSE VALVE

OUTPUTS (Universal/Analog) UO4 = FAN SPEED

H Line N Voltage

NETWORK MS/TP OR ETHERNET
POWER

~
Phase

­
Neutral

24 VAC (Only)

Floating Reheat

Fan Start

COM OPEN CLOSE

COM ~

NOTE: Use 24 VAC (only) on triac outputs (BO6­BO9 with SC)!
CAUTION: Do NOT connect 24 VAC to the analog outputs (UO3­UO5 and GNDs)!

Fan Speed

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INPUT/OUTPUT OBJECTS/CONNECTIONS

BAC-9001 SINGLE DUCT

Inputs (Objects/Terminals)

AI1

Space Sensor (on Room Sensor port)

AI2

Space Setpoint Offset (on port)

AI3/UI3

Discharge Air Temperature

AI4/UI4

Analog Input #4

AI5/UI5

Analog Input #5

AI6/UI6

Analog Input #6

AI7

Primary Duct Pressure (internal sensor)

AI8

Primary Damper Position (internal sensor)

Outputs (Objects/Terminals)

AO3/UO3 Analog Heat*

AO4/UO4 Fan Speed

AO5/UO5 Analog Output #5

BO1

Primary Damper CW (internal actuator)

BO2

Primary Damper CCW (internal actuator)

BO6

Fan

BO7

Heating Stage 1*

BO8

Heating Stage 2*

BO9

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

AI1

Space Sensor (on Room Sensor port)

AI2

Space Setpoint Offset (on port)

AI3/UI3

Discharge Air Temperature

AI4/UI4

Analog Input #4

AI5/UI5

Analog Input #5

AI6/UI6

Analog Input #6

(No internal pressure sensor in this model)

AI8

Primary Damper Position (internal sensor)

Outputs

AO3/UO3 Analog Heat*

AO4/UO4 Analog Output #4

AO5/UO5 Analog Output #5

BO1

Primary Damper CW (internal actuator)

BO2

Primary Damper CCW (internal actuator)

BO6

Binary Output #6

BO7

Heating Stage 1*

BO8

Heating Stage 2*

BO9

Heating Stage 3*

*See NOTE ABOUT REHEAT above.

BAC-9000 Series Controller Installation Guide

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AI1 AI2 AI3/UI3 AI4/UI4 AI5/UI5 AI6/UI6 AI7 AI8
AO3/UO3 AO4/UO4 AO5/UO5 BO1 BO2 BO6 BO7 BO8 BO9

BAC-9001 DUAL DUCT
Inputs Space Sensor (on Room Sensor port) Space Setpoint Offset (on port) Discharge Air Temperature Analog Input #4 Secondary Duct Pressure Secondary Damper Position Primary Duct Pressure (internal sensor) Primary Damper Position (internal sensor)
Outputs Analog Output #3 Analog Output #4 Analog Output #5 Primary Damper CW (internal actuator) Primary Damper CCW (internal actuator) Binary Output #6 Secondary Damper CW Secondary Damper CCW Binary Output #9

NOTE:

For more information, see Sample (BAC-9001A) Wiring on page 8 and the BAC-9000 series videos in the KMC Conquest Controller Wiring playlist.

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.

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REPLACEMENT PARTS

HPO-0055 HPO-9901

Replacement Network Bulb Module for Conquest Controllers, Pack of 5
Conquest Hardware Replacement Parts Kit

NOTE: HPO-9901 includes the following:

Terminal Blocks

DIN Clips

(1) Black 2 Position (2) Small

(2) Grey 3 Position

(1) Large

(2) Green 3 Position

(4) Green 4 Position

(2) Green 5 Position

(2) Green 6 Position

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 LiteTM 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

©2024 KMC Controls, Inc.

Specifications and design subject to change without notice

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References

• Kmccontrols.com
• KMC Controls | Building Automation and Control Solutions
• KMC Controls | Building Automation and Control Solutions

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