KMC CONTROLS BAC-5901 Gen6 Airflow Measurement System Installation Guide

Mount the controller inside a metal enclosure for RF shielding
and physical protection.
If mounting on a flat surface:
1. Position the controller on a flat surface ensuring easy access
  to the color-coded terminal blocks for wiring.
2. The black terminals are for power, green terminals for
  inputs/outputs, and grey terminals for communication.

If mounting on a 35 mm DIN rail:
1. Complete the steps specified for mounting on a DIN rail
  provided in the installation guide.

Mounting the Inclinometer

Mounting the Supply Airflow Pickup Tubes

Frequently Asked Questions (FAQ)

Q: Can the Airflow Measurement System be used in outdoor
installations?

A: Yes, the system can be used outdoors. Ensure proper
protection from environmental elements as per the installation
guidelines.

Q: How do I troubleshoot communication issues with the
controller?

A: Check the wiring connections, network settings, and power
supply to troubleshoot communication problems. Refer to the
troubleshooting section in the manual for detailed steps.

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Airflow Measurement System
Installation Guide (Gen6)
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Contents

Example Diagrams ………………………………………….2 Standard Application …………………………………2 Outdoor Air Damper Pressure Assist Application ..2 Return Air Damper Pressure Assist Application ….3
Mounting the System Components ………………………4 Mounting the Controller ……………………………..4 Mounting the Inclinometer…………………………..5 Mounting the Supply Airflow Pickup Tubes……….6 Mounting Pickup Tubes for Pressure Assist………8 Mounting the Pressure Transducer(s) ……………10 Mounting the OAT, RAT, and MAT Sensors ………11 Mounting a Proportional Actuator ………………..13
Connecting System Components to the Controller ….14 Connecting the Airflow Pickup Tubes ……………14 Connecting the Inclinometer ……………………… 15 Connecting the Outside Air Temperature Sensor.15 Connecting the Return Air Temperature Sensor ..16 Connecting the Mixed Air Temperature Sensor…16 Connecting the Proportional Actuator……………17

Connecting Networks …………………………………….18 Connecting an Ethernet Network………………….18 Connecting an MS/TP Network ……………………18
Connecting Power ………………………………………..20 Connecting Power to the Controller ………………20 Connecting Power to the Inclinometer …………..20 Connecting Power to the Pressure Transducer(s) 20 Connecting Power to the Proportional Actuator..21
Controller Power and Communication Status ………..22 Controller MS/TP Network Isolation Bulbs……………23 Wiring Diagrams…………………………………………..24 Input/Output Objects/Connections …………………….30 Configuring and Operating ………………………………30 Important Notices…………………………………………31 We Value Your Feedback!………………………………..31

KMC Controls, 19476 Industrial Drive, New Paris, IN 46553 / 877-444-5622 / Fax: 574-831-5252 / www.kmccontrols.com

Example Diagrams
Standard Application
REVISE
Outdoor Air Damper Pressure Assist Application

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Return Air Damper Pressure Assist Application

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Mounting the System Components
Mounting the 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 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 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 grey 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.

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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.
6
Mounting the Inclinometer
NOTE: If the outside air damper has vertical-axis damper blades, you will first need to install an HLO-1050 Linkage Kit on the outside air damper. (See the HLO-1050 Linkage Kit Installation Guide.) Then continue below.
1. Position the inclinometer on a horizontal-axis outside air damper blade so that the wire is parallel with the blades and the arrow on the inclinometer sticker points up.

NOTE: If the unit has more than one outside air damper, mount the inclinometer on a horizontal-axis return air damper blade. (However, if the unit also has more than one return air damper, an AFMS cannot be installed.)
2. Attach the inclinometer to the damper blade with two #8 sheet metal screws.
3. Route the cord away from the damper so that it will not bind the damper.
4. Route the cord to the controller.
NOTE: Attach adequate strain relief (e.g. with wire ties) if needed to prevent the inclinometer from accidentally being pulled off of the damper blade during equipment maintenance.

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Mounting the Supply Airflow Pickup Tubes
There must be enough pressure flow pickup tubes must installed, for the size of the opening, to get an accurate average value for the air-stream. Multiple pickup tubes (at least 2) connected in a parallel pitot array are recommended. The supply air pressure flow pickup tubes can be installed in one of three ways: y On the Supply Air Fan Bell (using SSS-1112/3/4) on page 6. y On the Supply Air Fan Bell (using SSS-1115/6/7) on page 6. y In the Supply Air Duct (using SSS-101x) on page 6.
On the Supply Air Fan Bell (using SSS-1112/3/4)
1. Position the pickup tubes’ mounting foot on the edge of the fan bell so that the ends of the tubes are pointing toward the center of the fan inlet. NOTE: All pickup points must be within the air-stream for accurate averaging of the differential pressure flow. If the pickup tubes are too long, use a shorter model.
2. Attach the tubes to the fan bell using two self-tapping screws inserted through the 3/16″ mounting holes. 3. Repeat steps 1 to 2 to mount the remaining pickup tubes.
On the Supply Air Fan Bell (using SSS-1115/6/7)
1. Position the pickup tubes so that the mounting feet span the fan inlet and all pickup points are within the air-stream. NOTE: All pickup points must be within the air-stream for accurate averaging of the differential pressure flow. If the pickup tubes are too long, use a shorter model.
2. Attach the first mounting foot to the fan bell using two self-tapping screws inserted through the 3/16″ mounting holes.
3. Attach the second mounting foot to the opposite edge of the fan bell (or the strut) using two self-tapping screws inserted through the 3/16″ mounting cutouts.
4. Repeat steps 1 to 3 to mount the remaining pickup tubes.
In the Supply Air Duct (using SSS-101x)
NOTE: The pressure flow pickup tubes should be mounted in filtered air in the location of laminar flow, which is about 6 straight duct diameters down the air duct.
1. Determine the duct’s flow direction and install the pickup tubes based on the flow arrow imprint. NOTE: The pickup tubes must be mounted with the arrow pointing in the direction of the airflow.

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3-1/2″ (89 mm)

2-3/4″ (70 mm)

7/16″ (11 mm)

1-1/2″ (38 mm) for SSS-101x
or 1-1/4″ (32 mm)
for SSS-100x

Mounting Holes, 3/16″ (5 mm)
2. Cut a 7/8″ hole in the duct to accept the pickup tubes.

1-3/8″ (35 mm)

Cut 7/8″ (22 mm) diameter
Drill two holes for self-tapping screws inserted through the pickup tubes’ 3/16″ (5 mm) mounting holes.

3. Attach the pickup tubes to the duct using two self-tapping screws inserted through the 3/16″ mounting holes.
4. Repeat steps 1 to 3 to mount the remaining pickup tubes.

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Mounting Pickup Tubes for Pressure Assist
Mounting for OAD Pressure Assist
Complete these additional steps only if installing a BAC-5901AC-AFMS or BAC-5901ACE-AFMS for an OAD pressure assist application. (See the KMC AFMS Selection Guide for details.)

Mounting the First Airflow Pickup Tube
1. Find a location for the first pickup tube outside of the outside air damper, in a location without turbulent flow from the incoming outside air-stream.
NOTE: For example, in a corner under the outside air intake hood. (See the drawing above.)
2. Determine the airflow direction in order to install the pickup tube so that the FLOW arrow imprint is perpendicular to the direction of the airflow (for static pressure measurement).
NOTE: In this case, the FLOW arrow imprint can point either up or down. Mark the SSS-10xx to assure others that this perpendicular orientation is indeed the intended orientation.
3. Cut a 7/8″ (22 mm) hole in the duct to accept the pickup tube.
4. Attach the pickup tube to the sheet metal using two self-tapping screws inserted through the 3/16″ (5 mm) mounting holes.

Mounting the Second Airflow Pickup Tube

1. Find a location for the second pickup tube in the mixed air chamber, in a location without turbulent air flow.

NOTE: For example, in a corner of the mixed air chamber just inside of the outside air damper. (See the drawing above.)

2. Determine the airflow direction in order to install the pickup tube so that the FLOW arrow imprint is perpendicular to the direction of the airflow (for static pressure measurement).

NOTE: In this case, the FLOW arrow imprint can point either up or down. Mark the SSS-10xx to assure others that this perpendicular orientation is indeed the intended orientation.

3. Cut a 7/8″ (22 mm) hole in the duct to accept the pickup tube.

4. Attach the pickup tube to the sheet metal using two self-tapping screws inserted through the 3/16″ (5 mm) mounting holes.

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Mounting for RAD Pressure Assist
Complete these steps only if installing a BAC-5901AC-AFMS or BAC-5901ACE-AFMS for a RAD pressure assist application. (See the KMC AFMS Selection Guide for details.)
Mounting the First Airflow Pickup Tube
1. Find a location for the first pickup tube near the return air damper, on the damper’s upstream side.
2. Determine the airflow direction in order to install the pickup tube so that the FLOW arrow imprint is perpendicular to the direction of the airflow (for static pressure measurement).
NOTE: In this case, the FLOW arrow imprint can point either up or down (in a horizontal duct), or either left or right (in a vertical duct).
NOTE: It is recommended that a marking be applied to the SSS-10xx to assure others that this perpendicular orientation is indeed the intended orientation.
3. Cut a 7/8″ (22 mm) hole in the duct to accept the pickup tube.
4. Attach the pickup tube to the sheet metal using two self-tapping screws inserted through the 3/16″ (5 mm) mounting holes.
Mounting the Second Airflow Pickup Tube
1. Find a location for the second pickup tube near the return air damper, on the damper’s downstream (i.e. mixed air) side.
2. Determine the airflow direction in order to install the pickup tube so that the FLOW arrow imprint is perpendicular to the direction of the airflow (for static pressure measurement).
NOTE: In this case, the FLOW arrow imprint can point either up or down (in a horizontal duct), or either left or right (in a vertical duct).
NOTE: It is recommended that a marking be applied to the SSS-10xx to assure others that this perpendicular orientation is indeed the intended orientation.
3. Cut a 7/8″ (22 mm) hole in the duct to accept the pickup tube.
4. Attach the pickup tube to the sheet metal using two self-tapping screws inserted through the 3/16″ (5 mm) mounting holes.

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Mounting the Pressure Transducer(s)
NOTE: Complete these steps only if using a BAC-5901AC(E)-AFMS controller.
NOTE: Avoid locations with severe vibrations or excessive moisture. The enclosure has a standard 1/2-inch conduit opening and may be installed with either a conduit coupler or a cable-gland-type fitting.
CAUTION Do not use in explosive or hazardous environments, with combustible or flammable gasses, as a safety or emergency stop device, or in any other application where failure of the product could result in personal injury.
1. Ensure there is enough space around the unit to make the pressure and electrical connections.
2. Use screws threaded through the case’s mounting holes to fasten the assembly to a location near the array of pressure flow pickup tubes. Do not over-tighten.
3. If additional pressure flow pickup tubes were installed at the outside air damper or return air damper location for pressure assist measurements, repeat steps 1 and 2 for a second pressure transducer located near those pickup tubes.

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Mounting the OAT, RAT, and MAT Sensors
STE-1411/12/13/14 Bendable Copper Sensor
Use a bendable copper sensor for easily-accessible mixed air sections and outside air hoods. If the mixed air section is not easily accessible, a flexible cable sensor may be used. If the unit does not have an easilyaccessible outside air hood, a rigid steel probe may be used.

Use Tie Wraps to Secure
Tubing

6″ Min. Bend Radius

1. Cut a hole in the mixed air chamber of the unit large enough to feed the copper probe from the back of the enclosure.
2. Insert the sensor probe into the mixed air chamber, bend the probe tubing to cover the air path, and secure as needed.
NOTE: Maintain a minimum bend radius of six inches to prevent damage to the wires or sensors.
3. Fasten the enclosure to the unit by drilling holes in the side of the unit and threading screws through the mounting holes in the case.
4. For the cable leading to the AFMS controller, attach conduit to the 1/2″ NPT threaded connection hole at the bottom of the enclosure as needed.
5. Open the cover by pulling slightly on the latch on the right side of the enclosure while pulling on the cover.

STE-1415/6/7 Flexible Cable Sensor

A flexible cable sensor may be used if the mixed air section is not easily accessible.

Use Tie Wraps to Secure
Cable

2″ Min. Bend Radius

1. Cut a hole in the mixed air chamber of the unit large enough to feed the sensor cable from the back of the sensor enclosure.

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2. Insert the sensor cable into the mixed air chamber, stringing the cable to cover the air path, and secure as needed.
NOTE: The flexible cable can be easily shaped to fit any duct size but observe a minimum bend radius of two inches to prevent damage to wires or sensors.
3. Fasten the enclosure to the unit by drilling holes in the side of the unit and threading screws through the mounting holes in the case.
4. For the cable leading to the AFMS controller, attach conduit to the 1/2″ NPT threaded connection hole at the bottom of the enclosure as needed.
5. Open the cover by pulling slightly on the latch on the right side of the enclosure while pulling on the cover.
STE-1404/05 Rigid Steel Probe
Use a rigid probe for the return air duct. A rigid probe may also be used for the outside air duct, but only if the unit does not have an easily-accessible outside air hood.

1.10″ 27.9 mm

2.20″ 63.5 mm
2.80″ 71.1 mm

0.25″ 6.35 mm

STE-1401/1405 (No Enclosure)
Various Probe Lengths

10′ 3.05 m

1. Locate the sensor in a straight section of duct, away from heating, cooling, or humidifier sources.
2. Cut a 1/4-inch hole for the probe in the side of the duct as well as smaller holes for screws at the appropriate locations.
3. Insert the probe and fasten the assembly to the duct using screws threaded through the mounting holes in the housing.
4. Open the sensor cover (STE-1404 only) by pulling slightly on the latch on the right side of the enclosure while pulling on the cover.
5. For the cable leading to the AFMS controller, attach conduit to the 1/2″ NPT threaded connection hole at the bottom of the enclosure as needed.

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Mounting a Proportional Actuator
Complete these steps only if there is not a proportional actuator already mounted on the correct damper for the application needed:
· For standard or OAD applications, mount the proportional actuator on the outside air damper (or, alternatively, on the return air damper, if it moves together with the outside air damper).
· For RAD pressure assist applications, mount the proportional actuator on the return air damper (or, alternatively, on an outside air damper that moves together with the return air damper).
For instructions on how to mount your particular model of MEP-series proportional actuator:
1. Select the appropriate link from the list, or search for it on the KMC Controls website:
· MEP-4552
· MEP-4952
· MEP-7552
2. Access the installation guide found on that model’s product page.
3. Follow the instructions for mounting, on the appropriate damper for the application needed:
· For standard or OAD pressure assist applications, mount the proportional actuator on the outside air damper (or, alternatively, on the return air damper, if it moves together with the outside air damper).
· For RAD pressure assist applications, mount the proportional actuator on the return air damper (or, alternatively, on an outside air damper that moves together with the return air damper).

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Connecting System Components to the Controller

Connecting the Airflow Pickup Tubes

For a BAC-5901AC(E)-AFMS
Use appropriately sized polyethylene tubing for the pressure connections. The length of the tubing should not be longer than necessary. Arrange the tubing to minimize stress on the connections and prevent kinking.

Connecting the Supply Airflow Pickup Tubes to the Pressure Transducer
1. With tubing, connect the Port Hs of all the pickup tubes in parallel in a loop, then connect to the High input on the supply air pressure transducer.
2. With tubing, connect the Port Ls of all the pickup tubes in parallel in a loop, then connect to the Low input on the supply air pressure transducer.

Connecting the Airflow Pickup Tubes for OAD Pressure Assist Applications
Complete these steps if two additional SSS-1000 series pickup tubes were installed at the location of the outside air damper for pressure assist.
1. For the pickup tube mounted outside of the outside air damper, connect one of its ports, with tubing, to the High input on the transducer used for pressure assist.
NOTE: It does not matter, in this application, which pickup tube port (H or L) is connected to the transducer’s High input.
2. For the pickup tube mounted inside of the outside air damper, connect one of its ports, with tubing, to the Low input on the transducer used for pressure assist.
NOTE: It does not matter, in this application, which pickup tube port (H or L) is connected to the transducer’s Low input.
NOTE: The other ports of the two pickup tubes are left unconnected and open to air.

Connecting the Airflow Pickup Tubes for RAD Pressure Assist Applications

Complete these steps if two additional SSS-1000 series pickup tubes were installed at the location of the return air damper for pressure assist.

1. For the pickup tube mounted on the upstream side of the return air damper, connect one of its ports, with tubing, to the High input on the transducer used for pressure assist.

NOTE: It does not matter, in this application, which pickup tube port (H or L) is connected to the transducer’s High input.

2. For the pickup tube mounted on the downstream (i.e. mixed air) side of the return air damper, connect one of its ports, with tubing, to the Low input on the transducer used for pressure assist.

NOTE: It does not matter, in this application, which pickup tube port (H or L) is connected to the transducer’s Low input.

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NOTE: The other ports of the two pickup tubes are left unconnected and open to air.

Connecting the Pressure Transducer(s) to the Controller
1. Connect the signal wire from OUT on the supply air pressure transducer to UI9 on the controller. 2. If installing a second transducer for (OAD or RAD) pressure assist applications, connect the signal wire
from OUT on the second transducer to UI10 on the controller.

For a BAC-9311AC(E)-AFMS

NOTE: Use 1/4 inch (6.35 mm) FR tubing. Tubing should not be longer than 20 feet (6 meters).
1. Remove the black shipping plugs from the PRESSURE SENSOR ports.
2. With tubing, connect the Port Hs of all the pickup tubes in parallel in a loop, then connect to the HIGH 7 port on the controller. (See Wiring Diagrams on page 24.)
3. With tubing, connect the Port Ls of all the pickup tubes in parallel in a loop, then connect to the LOW 8 port on the controller. (See Wiring Diagrams on page 24.)

Connecting the Inclinometer
1. Connect the inclinometer’s yellow signal wire to UI7 on the controller. 2. Connect the inclinometer’s green signal wire to UI8 on the controller. 3. Connect the inclinometer’s blue ground wire to GND (between UI7 and UI8) on the controller. 4. Connect the inclinometer’s red power wire to either UO8 (for a BAC-5901AC[E]-AFMS) or U10 (for a BAC-
9311AC[E]-AFMS).

Connecting the Outside Air Temperature Sensor

NOTE: Use 18 to 24 AWG shielded wiring for all connections. Do not locate the device wires in the same conduit with wiring used to supply inductive loads such as motors.

1. Bring the cable that will go to the AFMS controller through the bottom hole.

2. Make connections to the two wire leads with either butt-splices or solder. (Using wire nuts is not recommended.)

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NOTE: The two-wire sensor is not polarity sensitive. 3. Plug the conduit with sealant to prevent air infiltration. 4. Swing the door closed until securely latched. 5. If desired for added security, install the two (provided) screws in the door’s integrated screw tabs. 6. Connect the sensor’s signal wire to UI4 on the controller. 7. Connect the sensor’s ground wire to GND (next to UI4) on the controller.

Connecting the Return Air Temperature Sensor
NOTE: Use 18 to 24 AWG shielded wiring for all connections. Do not locate the device wires in the same conduit with wiring used to supply inductive loads such as motors.
1. Feed the wire that will go to the AFMS controller through the bottom hole (if applicable). 2. Make connections to the two wire leads with either butt-splices or solder. (Using wire nuts is not
recommended.) NOTE: The two-wire sensor is not polarity sensitive. 3. Plug the conduit with sealant to prevent air infiltration. 4. Swing the door (if applicable) closed until securely latched. 5. If desired for added security (and if applicable), install the two (provided) screws in the door’s integrated screw tabs. 6. Connect the sensor’s signal wire to UI5 on the controller. 7. Connect the sensor’s ground wire to GND (next to UI5) on the controller.

Connecting the Mixed Air Temperature Sensor

NOTE: Use 18 to 24 AWG shielded wiring for all connections. Do not locate the device wires in the same conduit with wiring used to supply inductive loads such as motors.
1. Feed the wire that will go to the AFMS controller through the bottom hole. 2. Make connections to the two wire leads with either butt-splices or solder. (Using wire nuts is not
recommended.) NOTE: The two-wire sensor is not polarity sensitive. 3. Plug the conduit with sealant to prevent air infiltration. 4. Swing the door closed until securely latched. NOTE: If desired for added security, install the two (provided) screws in the door’s integrated screw tabs. 5. Connect the sensor’s signal wire to UI6 on the controller. 6. Connect the sensor’s ground wire to GND (next to UI6) on the controller.

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Connecting the Proportional Actuator
Using an Existing Proportional Actuator
NOTE: Follow the procedure in this section when installing the AFMS into a unit that already has a proportional actuator, which is controlled by another controller, mounted to the outdoor or return air damper.
CAUTION Power off the actuator and the other controller before taking the following steps!
1. Disconnect from the existing actuator the signal wire that comes from the output of the other controller. 2. Disconnect from the existing actuator the ground wire that comes from the other controller. 3. Connect the signal wire (coming from the other controller) to UI3 on the AFMS controller. 4. Connect the ground wire (coming from the other controller) to the GND terminal (next to UI3) on the AFMS
controller. 5. Run a new signal wire from UO7 on a BAC-5901AC(E)-AFMS, or from UO9 on a BAC-9311AC(E)-AFMS
to the signal terminal on the actuator. 6. Connect the signal common wire of that new (twisted pair) wire to the GND terminal (next to UO7/UO9) on
the AFMS controller.
Using a New Proportional Actuator
For instructions on how to wire your particular model of actuator to the controller: 1. Click on the appropriate model from the list, or search for it on the KMC Controls website:
· MEP-4552 · MEP-4952 · MEP-7552 2. Access the installation guide found on that model’s product page. 3. Follow all instructions on wiring to the controller that apply to your model of actuator. NOTE: For information on which controller inputs and outputs to wire to, see Wiring Diagrams on page 24
and Input/Output Objects/Connections on page 30. NOTE: For information on which controller inputs and outputs to wire to, see Wiring Diagrams on page 24
and Input/Output Objects/Connections on page 30.

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Connecting Networks
Connecting an Ethernet Network
For “E” models only, connect an Ethernet patch cable to the 10/100 ETHERNET port 9 . CAUTION Do NOT plug a cable meant for Ethernet communications into the Room Sensor port! The Room Sensor port powers a NetSensor. 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.
9

NOTE: Ethernet-enabled “E” models with the latest firmware can be configured with a web browser from pages served from within the controller. The controllers have the following default network address values: · IP address–192.168.1.251 · Subnet mask–255.255.255.0 · Gateway–192.168.1.1
Connecting an MS/TP Network
1. For a BAC-5901AC-AFMS or BAC-9311AC-AFMS, connect the BACnet network to the gray BACnet MS/TP terminal block 10 .
10

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 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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3. If the controller is at either end of a BACnet MS/TP network (only one wire under the terminals), turn the EOL switch to ON.
NOTE: The EOL switch is shipped from the factory in the OFF position.

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Connecting Power
Connecting Power to the Controller
To connect a 24 VAC, Class-2 transformer to the black power terminal block of the controller:
1. Connect the neutral side of the transformer to the controller’s common terminal 11 . 2. Connect the AC phase side of the transformer to the controller’s phase terminal 12 .

NOTE: Connect only one controller to each 24 VAC, Class-2 transformer with 1224 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.
Connecting Power to the Inclinometer
1. Connect the inclinometer’s red power wire to UO8 for a BAC-5901AC(E)-AFMS, or UO10 for a BAC9311AC(E)-AFMS.
2. Connect the inclinometer’s blue ground wire to GND/SC on the controller.
Connecting Power to the Pressure Transducer(s)
NOTE: Complete these steps only if using a BAC-5901AC(E)-AFMS controller. NOTE: Use at least 22 AWG, shielded, twisted-pair wiring for all connections. Do not locate device wires in
the same conduit with wires supplying inductive loads. CAUTION
When grounding the secondary of an AC transformer or when wiring multiple devices, ensure that the circuit ground point is the same on all devices and the controller.
1. Connect the controller’s phase terminal to the transducer’s PWR terminal. 2. Connect the controller’s common terminal to the COM terminal on the transducer.

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3. If there is a second transducer for pressure assist applications, repeat steps 1 and 2 for that transducer.
Connecting Power to the Proportional Actuator
For instructions on how to wire to power and complete setup of your particular model of actuator: 1. Select the appropriate model from the list, or search for it on the KMC Controls website:
· MEP-4552 · MEP-4952 · MEP-7552 2. Access the installation guide found on that model’s product page. 3. Follow all instructions on wiring to power and remaining setup that apply to your model of actuator.

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Controller Power and Communication Status
The status LEDs on a BAC-5901AC(E)-AFMS and BAC-9311AC(E)-AFMS 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
After controller power-up or restart is complete, the READY LED 13 flashes steadily about once per second, indicating normal operation.
13

Amber (BACnet MS/TP) COMM LED
· During normal operation, the COMM LED 14 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).
14
Green ETHERNET LED
NOTE: The Ethernet status LEDs 15 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.

KMC Airflow Measurement System Installation Guide (Gen6) 22

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Amber ETHERNET LED
· The amber Ethernet LED 16 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).

Controller MS/TP Network Isolation Bulbs
The two network isolation bulbs 17 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.
· 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.

KMC Airflow Measurement System Installation Guide (Gen6) 23

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Wiring Diagrams
KMC Conquest Airflow Measurement System Model: BBAACC–55990011ACC(E(E))-AFMS

AIRFLOW TUBE

TUBING HL

POLY

AIRFLOW TUBE

DSUUCPTPLY

AIRFLOW TUBE
SUPPLY DUCT

SUPPLY DUCT

AIRFLOW TUBE

NOTES:
1. Controller settings must be initially set using an STE-9XX1.
2. See the AFMS Selection, Installtion and Application Guides for additional installation details.
3. See www.kmccontrols.com for accessories and additional details.

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KMC Conquest Airflow Measurement System Model: BAACC–55990011AC(C(E)E)-AFMS

H Line N Voltage

24VAC

Outside Air Damper

SENSOR

ROOM

~ GND UO8 SC UO7 GND UO6 SC UO5 GND UO4 SC UO3 GND UO2 SC UO1
STE-9XX1W

Connect sensor to the RJ-45 jack using a max. 150′ Ethernet cable.

12345678

STATUS

POLY

TUBING SUPPLY

DUCT

AIRFLOW

TUBE

OUT COM PWR

TPE-1475-21 HIGH LOW

BACnet General Purpose Controller
24 VAC/VDC Class 2 50/60 Hz Made in USA

BAC-5901 Controller
ON OFF
S + UI10 GND UI9 UI8 GND UI7 UI6 GND UI5 UI4 GND UI3
S +B -A
ON OFF
External connections:
AO6 = 0-10VDC CFM Output AO7 = Outside Air Damper AO8 = Inclinometer Power UI3 = Orig Equip Damper Signal UI4 = Outside Air Temperature Sensor UI5 = Return Air Temperature Sensor UI6 = Mixed Air Temperature Sensor UI7 = Inclinometer V1 Signal UI8 = Inclinometer V2 Signal UI9 = Differential Pressure Sensor

MS/TP 10/100

EIO EOL

EOL

Connect controller to network using standard Ethernet cable. (optional)

SHLD BLK RED

TO NEXT CONTROLLER

SHLD BLK RED

FROM PREVIOUS CONTROLLER

If controllers are to be networked together via MS/TP, turn ON EOL switch on the controllers at both physical ends of the network. Connect shield to earth ground at only one point.

RED GRN BLU YEL

Inclinometer

Mixed Air Temperature
Sensor

Return Air Temperature
Sensor

Outdoor Air Temperature
Sensor

Original Equipment + Damper Signal
NOTES: 1. Controller settings must be initially set using
an STE-9XX1. 2. See the AFMS Selection, Installtion and
Application Guides for additional installation details. 3. See www.kmccontrols.com for accessories and additional details.

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KMC Conquest Airflow Measurement System with Pressure Assist [or Additional Pressure Transducer and Pickups for Pressure Assist] Model: BAC-5901C(E)-AFMS

CONNECT ONLY THE HIGH PORT

CONNECT ONLY THE LOW PORT

AIRFLOW

TUBE

(TYPICAL)

AIRFLOW TUBE

TUBPINOGLY HL

DUCT AIRFLOW
TUBE
AIRFLOW TUBE
DUCT

DUCT

AIRFLOW TUBE
© 2022 KMC CONTROLS, INC.
KMC Airflow Measurement System Installation Guide (Gen6) 26

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KMC Conquest Airflow Measurement System with Pressure Assist [or Additional Pressure Transducer and Pickups for Pressure Assist] Model: BAC-5901C(E)-AFMS

LOCATED JUST OUTSIDE OF OAD

AIRFLOW TUBES
H

L
LOCATED IN MIXED AIR PLENUM NEAR OAD

OUT COM PWR OUT COM PWR

POLY TUBING

PRESSURE ASSIST
TPE-1475-21 HIGH LOW

SUPPLY AIR PRESSURE
TPE-1475-21 HIGH LOW

LH DSUUCPTPLY

TUBPINOGLY

AIRFLOW

TUBE

H Line N Voltage

24VAC

Outside Air Damper

SENSOR

ROOM

~ GND UO8 SC UO7 GND UO6 SC UO5 GND UO4 SC UO3 GND UO2 SC UO1
STE-9XX1W

Connect sensor to the RJ-45 jack using a max. 150′ Ethernet cable.

12345678

STATUS

BACnet General Purpose Controller
24 VAC/VDC Class 2 50/60 Hz Made in USA

MS/TP 10/100

EIO EOL

EOL

Connect controller to network using standard Ethernet cable. (optional)

SHLD BLK RED

TO NEXT CONTROLLER

SHLD BLK RED

FROM PREVIOUS CONTROLLER

If controllers are to be networked together via MS/TP, turn ON EOL switch on the controllers at both physical ends of the network. Connect shield to earth ground at only one point.

RED GRN BLU YEL

Inclinometer

Mixed Air Temperature
Sensor

Return Air Temperature
Sensor

Outdoor Air Temperature
Sensor

KMC Conquest Airflow Measurement System Model: BBACC–9311ACC(E(E) )-AFMS

AIRFLOW TUBE

TUBING HL

POLY

AIRFLOW TUBE

DSUUCPTPLY

AIRFLOW TUBE
SUPPLY DUCT

SUPPLY DUCT

AIRFLOW TUBE

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KMC Conquest Airflow Measurement System Model: BACC–9311AC(C(E)E)-AFMS

Line Voltage

24VAC

Outside Air Damper

ROOM SENSOR

~
UO10 GND UO9 UO8 GND UO7 BO6 SC BO5 BO4 BO3 SC BO2 BO1
STE-9XX1W

Connect sensor to the RJ-45 jack using a max. 150′ Ethernet cable.

PRESSURE SENSOR
HIGH LOW

POLY

TUBING SUPPLY

DUCT

AIRFLOW

TUBE

BAC-9311 Controller

RED GRN BLU YEL

Inclinometer

Mixed Air Temperature
Sensor

UI8 GND
UI7 UI6 GND UI5 UI4 GND UI3
S +B -A
ON OFF
External connections: UO8 = 0-10VDC CFM Output UO9 = Outside Air Damper UO10 = Inclinometer Power UI3 = Orig Equip Damper Signal UI4 = Outside Air Temperature Sensor UI5 = Return Air Temperature Sensor UI6 = Mixed Air Temperature Sensor UI7 = Inclinometer V1 Signal UI8 = Inclinometer V2 Signal

MS/TP

EOL

10/100 ETHERNET

Connect controller to network using standard Ethernet cable. (optional)

SHLD BLK RED
SHLD BLK RED

TO NEXT CONTROLLER
FROM PREVIOUS CONTROLLER

If controllers are to be networked together via MS/TP, turn ON EOL switch on the controllers at both physical ends of the network. Connect shield to earth ground at only one point.

Return Air Temperature
Sensor
Outdoor Air Temperature
Sensor
Original Equipment + Damper Signal
NOTES: 1. Controller settings must be initially set using
an STE-9XX1. 2. See the AFMS Selection, Installtion and
Application Guides for additional installation details. 3. See www.kmccontrols.com for accessories and additional details.

19476 INDUSTRIAL DR. DRAWING TITLE: KMC CONQUEST AIRFLOW MEASUREMENT SYSTEM W/BAC-9311 WIRING

KMC Airflow Measurement System Installation Guide (Gen6) 29

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Input/Output Objects/Connections

BAC-5901AC(E)-AFMS

Inputs

AI1

Space Sensor (on Room Sensor port)

AI2 AI3/UI3 AI4/UI4 AI5/UI5 AI6/UI6

Space Setpoint Offset (on port) Incoming Damper Signal Outdoor Air Temp Return Air Temp Mixed Air Temp

AI7/UI7 AI8/UI8 AI9/UI9

Inclinometer V1 (yellow wire) Inclinometer V2 (green wire) Supply Air Pressure Transducer

AI10/UI10

Additional Transducer (if pressure assist is needed)

Outputs

AO6/UO6 AO7/UO7

0-10 VDC CFM Output Outdoor Air Damper

AO8/UO8 BO1 BO2

Inclinometer Power (red wire) Binary Output #1 Binary Output #2

BO3

Binary Output #3

BO4

Binary Output #4

BO5

Binary Output #5

Note: Connect inclinometer blue wire to a GND terminal.

Configuring and Operating

AI1 AI2 AI3/UI3 AI4/UI4 AI5/UI5 AI6/UI6 AI7/UI7 AI8/UI8 AI9

BAC-9311AC(E)-AFMS
Inputs
Space Sensor (on Room Sensor port) Space Setpoint Offset (on port) Incoming Damper Signal Outdoor Air Temp Return Air Temp Mixed Air Temp Inclinometer V1 (yellow wire) Inclinometer V2 (green wire) Differential Pressure Sensor (integrated port)

Outputs

AO7/UO7 AO8/UO8

Analog Output #7 0-10 VDC CFM Output

AO9/UO9 Outdoor Air Damper

AO10/UO10 Inclinometer Power (red wire)

BO1

Binary Output #1

BO2

Binary Output #2

BO3

Binary Output #3

BO4

Binary Output #4

BO5

Binary Output #5

BO6

Binary Output #6

Note: Connect inclinometer blue wire to a GND terminal.

For each tool used to configure and operate the AFMS, see the documentation found on the tool’s product page.

PROCESSES
Selecting the application

BAC5051AE router

Ethernet controller1
served web pages

CONFIGURATION TOOLS

ConquestTM NetSensor

KMC
ConnectTM or TotalControlTM

KMC
ConvergeTM for Niagara
Workbench

KMC Commander®2

KMC
Connect LiteTM
(NFC) app3

Configuring communication

Setting AFMS parameters

Calibrating sensors

Starting Learning Mode

Controlling airflow

Monitoring operation & faults

1 Ethernet (E) models can be configured with a web browser from pages served within the controller. 2 KMC Commander’s AFMS module currently supports the standard AFMS application only.

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

KMC Airflow Measurement System Installation Guide (Gen6) 30

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Help us improve this document. Click here to take a 3-minute survey. Your input helps us make our documents clearer and more useful.
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

Specifications and design subject to change without notice

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Documents / Resources

KMC CONTROLS BAC-5901 Gen6 Airflow Measurement System [pdf] Installation Guide
BAC-5901 Gen6 Airflow Measurement System, BAC-5901, Gen6 Airflow Measurement System, Airflow Measurement System, Measurement System

References

User Manual

KMC CONTROLS BAC-5901 Gen6 Airflow Measurement System Installation Guide

BAC-5901 Gen6 Airflow Measurement System

Specifications

Product Usage Instructions

Mounting the System Components

Mounting the Controller

Mounting the Inclinometer

Mounting the Supply Airflow Pickup Tubes

Frequently Asked Questions (FAQ)

Q: Can the Airflow Measurement System be used in outdoor
installations?

Q: How do I troubleshoot communication issues with the
controller?

Documents / Resources

References

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