BAC-19xxxx FlexStat Installation Guide

CONTENTS

• Quick Start
• Wiring Considerations
• Mounting
• Network Connections
• Connect (Optional) Ethernet Network
• Connect (Optional) MS/TP Network
• Sensor and Equipment Connections
• Input Connections
• Output Connections
• Power Connection
• Configuration and Programming
• MS/TP Network Access Port
• Maintenance
• Additional Resources
• Important Notices

QUICK START

Complete the following steps to select and install a KMC Conquest BAC-19xxxx FlexStat:

1. Select the appropriate model for the intended application and options (see the BAC-190000 Series FlexStats Data Sheet at kmccontrols.com).
2. Mount and wire the unit (see this document and the BAC-19xxxx FlexStat Sequence of Operation and Wiring Guide).
3. Configure and operate the unit (see this document and the BAC-19xxxx FlexStat Application Guide).
4. If necessary, troubleshoot any issues (see the BAC-19xxxx FlexStat Application Guide).

NOTE: This document gives basic mounting, wiring, and setup information. For additional information, see the KMC Controls web site for the latest documents.

The FlexStat is a modern thermostat with a display showing room temperature, humidity, setpoints, and operational status (e.g., COOL, HEAT, AUTO). It features a KMCConquest™ branding.

[CAUTION] The BAC-19xxxx models are NOT compatible with the backplates of older BAC-10xxx/12xxxx/13xxxx/14xxxx FlexStats! If replacing an older FlexStat, replace the backplate as well.

[NOTICE] OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES

WIRING CONSIDERATIONS

Refer to the BAC-19xxxx FlexStat Sequence of Operation and Wiring Guide for sample wiring and the BAC-19xxxx FlexStat Application Guide for additional wiring considerations.

[CAUTION] The BAC-19xxxx models are NOT compatible with the backplates of older BAC-10xxx/12xxxx/13xxxx/14xxxx FlexStats! If replacing an older FlexStat, replace the backplate as well.

• Due to numerous connections (power, network, inputs, outputs, and their grounds/commons), plan wiring carefully before installing conduit.
• Ensure conduit has adequate diameter for all wiring. 1-inch conduit and junction boxes are recommended. Use external junction boxes as needed for connections to the FlexStat's junction box.
• To prevent excessive voltage drop, use a conductor size adequate for wiring length, allowing for startup transient peaks.
• Using multiple conductor wires for inputs (e.g., 8 conductor) and outputs (e.g., 12 conductor) is recommended. Grounds for inputs can be combined on one wire.

MOUNTING

Illustration 1 - Dimensions and Mounting Information: This illustration shows the FlexStat unit, terminal blocks on the backplate, an optional Ethernet jack on the back of the cover, and a cover locking screw. It also includes a table detailing dimensions:

NOTE: For optimal temperature sensor performance, mount the FlexStat on an interior wall away from heat sources, sunlight, windows, air vents, and obstructions like curtains or furniture. For models with an occupancy sensor, ensure an unobstructed view of typical traffic areas. Consult the Room Sensor and Thermostat Mounting Location and Maintenance Application Guide.

NOTE: If replacing an existing thermostat, label wires for reference before removal.

1. Complete rough-in wiring at each location before FlexStat installation. Cable insulation must meet local building codes.
2. If the cover is locked, turn the hex screw in the bottom of the FlexStat clockwise until it clears the cover. (See Illustration 1 for screw location).

[CAUTION] Use only KMC Controls mounting screws. Other screws may damage the FlexStat. Do not overtighten the screw.

COVER INSTALLATION AND REMOVAL

Illustration 2 - Unlocking the Cover from the Backplate: Shows the hex screw used to secure the cover.

NOTE: The hex screw should always remain in the backplate.

Illustration 3 - Hex Screw Flush in the Backplate: Depicts the hex screw in its flush position.

Step 3: Pull the bottom of the cover away from the backplate (mounting base).

Illustration 4 - Removing the Cover from the Backplate: Shows the cover detached from the backplate.

Step 4: Route wiring through the center hole of the backplate.

Step 5: Mount the backplate on an electrical box using the provided screws, ensuring the embossed "UP" indicator and arrows point towards the ceiling. Models mount directly on vertical 2x4 inch boxes; a HMO-10000W wall mounting plate is required for 4x4 boxes.

Step 6: Make appropriate connections to terminals and the modular jack (for Ethernet models). Refer to Network Connections (page 4), Sensor and Equipment Connections (page 5), and Power Connection (page 6).

Illustration 5 - BAC-19xx63 Terminals and Connections: Shows terminal layout for BAC-19xx63 models. Includes MS/TP (+B, -A), Inputs (IN7-IN2, GND), 24 VAC (Common/-/C, Phase/~/R), and Outputs (Analog 9, GND 7-9, Analog 8, Analog 7, Relay 6, SC 4-6, Relay 5, Relay 4, Relay 3, SC 1-3, Relay 2, Relay 1). Notes indicate SC is Switched (relay) Common and IN1 is reserved for the internal temp sensor. An optional Ethernet Network Connector on the cover is also shown.

Illustration 6 - BAC-19xx36 Terminals and Connections: Shows terminal layout for BAC-19xx36 models, similar to Illustration 5 with an IP/Ethernet Connector on the cover.

Step 7: After wiring, position the top of the FlexStat cover over the backplate, swing the bottom down, and push the cover into place.

Illustration 7 - Reinstalling the Cover on the Backplate: Shows the cover being reattached.

Step 8: Turn the hex screw at the bottom counter-clockwise until it engages the cover and holds it in place.

Illustration 8 - Locking the Cover on the Backplate: Shows the hex screw securing the cover.

NETWORK CONNECTIONS

Connect (Optional) Ethernet Network

For BAC-19xxxxCE models, plug an Ethernet patch cable into the back of the FlexStat. The cable should be T568B Category 5 or better, with a maximum length of 328 feet (100 meters) between devices.

Illustration 9 - Ethernet Network Connection ("E" Models): Depicts an Ethernet cable plugged into the back of the FlexStat unit.

Connect (Optional) MS/TP Network

[CAUTION] To prevent damage from ground loops and communication issues in networked MS/TP FlexStats, correct phasing on MS/TP network and power connections for all controllers is critical.

NOTE: Refer to the BAC-19xxxx FlexStat Application Guide for additional wiring considerations.

For non-E models, connect the BACnet network to the BACnet MS/TP terminals using shielded twisted-pair cable. Use 18 or 22 AWG shielded twisted pair cable with maximum capacitance of 51 picofarads per foot (0.3 meters). Consult the EIA-485 Network Wire Recommendations Technical Bulletin and Planning BACnet Networks (Application Note AN0404A) for best practices.

• Connect the '-A' terminals in parallel with all other '-A' terminals on the network.
• Connect the '+B' terminals in parallel with all other '+B' terminals on the network.
• Connect the shields of the cable together at each device using a wire nut or the 'S' terminal in other KMC BACnet controllers.

NOTE: The 'S' (Shield) terminal in KMC controllers is for shield connection only and is not connected to the controller's ground. Verify shield connection compatibility with non-KMC controllers.

Illustration 10 - MS/TP Connections and EOL (MS/TP Models): Shows MS/TP connections (-A, +B, S) and End-Of-Line (EOL) switches. It illustrates different states for EOL switches (On/Off) and shield wire connections (Not Connected, Connected with Wire Nut, Connected to Ground on One End Only).

Step 2: Connect the cable shield to a good earth ground at one end only.

NOTE: Devices at the physical ends of MS/TP wiring segments require EOL termination. Ensure the FlexStat's EOL switch is correctly positioned.

Step 3: If the FlexStat is at the physical end of the MS/TP network line (one wire on each -A or +B terminal), set both EOL switches to 'On'. If not at the end (two wires on each terminal), ensure both switches are 'Off'.

SENSOR AND EQUIPMENT CONNECTIONS

Input Connections

1. Wire any additional sensors to the appropriate input terminals. Refer to the BAC-19xxxx FlexStat Sequence of Operation and Wiring Guide for specific applications.

NOTE: Use KMC software to configure devices. For passive input devices (e.g., switch contacts, 10K ohm thermistors), set termination to the 10K Ohm position. For active voltage devices, set to the 0 to 12 VDC position.

NOTE: Unused analog inputs can be converted to binary inputs by right-clicking the input object in KMC software and selecting 'Convert to...'.

NOTE: Wire sizes 14-22 AWG can be clamped in each terminal. No more than two 16 AWG wires can be joined at a common point.

Output Connections

1. Wire additional equipment (fans, dampers, valves) to the appropriate output terminals. Refer to the BAC-19xxxx FlexStat Sequence of Operation and Wiring Guide. Connect the device under control between the desired output terminal and the related SC (Switched Common for relays) or GND (Ground for analog outputs) terminal.

Illustration 11 - Switched (Relay) Common and Relay Bank: Shows a "One Switched Common Connection in Bank of Three Normally Open Relays". Terminals include Relay 3, SC (Phase) 1-3, Relay 2, and Relay 1. A note clarifies that for the relay bank, there is one Switched (relay) Common connection instead of a GND terminal used for analog outputs.

For the relay circuit, the phase side of the AC should connect to the SC terminal. FlexStat relays are NO, SPST (Form "A").

NOTE: Unused analog outputs can be converted to binary outputs by right-clicking the output object in KMC software and selecting 'Convert to Binary Object'.

[CAUTION] Do not attach a device that draws current exceeding the FlexStat's output capacity:

• Maximum output current for individual ANALOG/UNIVERSAL outputs is 100 mA (at 0-12 VDC) or 100 mA total for all analog outputs.
• Max. output current is 1 A for individual RELAYS at 24 VAC/VDC or a total of 1.5 A for relays 1-3 or 4-6.

[CAUTION] Relays are for Class-2 voltages (24 VAC) only. Do not connect line voltage to the relays!

[CAUTION] Do not mistakenly connect 24 VAC to an analog output ground. This is not the same as a relay's (SC) Switched Common. Refer to the backplate's terminal label for the correct terminal.

POWER CONNECTION

[CAUTION] To avoid damage from ground loops and communication issues in networked MS/TP FlexStats, correct phasing on MS/TP network and power connections for all controllers is critically important!

NOTE: Follow all local regulations and wiring codes.

2. Connect a 24 VAC, Class-2 transformer (or 24 VDC power supply) to the power terminals (see Illustration 12):

• A. Connect the neutral side of the transformer to the common (-/C) terminal.
• B. Connect the AC phase side of the transformer to the phase (~/R) terminal.

Illustration 12 - Power Terminals: Shows connections for a 24 VAC transformer (Phase, Neutral) and a DC Power Supply (Phase, Ground) to the FlexStat's terminals (Common, Phase).

NOTE: Connect only one controller to each transformer with 14-22 AWG copper wire.

NOTE: For principles and practices on connecting transformers, see Tips for Connecting 24-Volt Power Application Note (AN0604D).

NOTE: To connect 24 VDC (±15%, +20%) instead of VAC power:

• Connect 24 VDC to the ~ (phase/R) terminal.
• Connect GND to the ⊥ (common) terminal.

NOTE: Use shielded connecting cables or enclose all cables in conduit to maintain RF emissions specifications.

NOTE: If power is applied, the FlexStat will power up when reinstalled on the backplate. See Mounting on page 2.

CONFIGURATION AND PROGRAMMING

To set up the FlexStat from the touchscreen:

1. Push and hold the upper left corner of the screen (space temperature reading) to start.
2. Select the desired options and values. See the BAC-19xxxx FlexStat Application Guide for details.

Illustration 13 - Screen Menus Access (Default): Displays typical FlexStat screen menus including 'Settings (Press Space Temp)', 'Active Cooling Setpoint', 'Active Heating Setpoint', 'Fan Auto or (Constant) On', 'Occupancy Override', 'Units (°F or °C)', and 'Heat/Cool/Auto/Off Mode'.

NOTE: Options in menus are dependent on the FlexStat model and selected application.

Advanced configuration can be done through software. See the BAC-190000 Series FlexStats Data Sheet for KMC Controls tools for configuring, programming (with Control Basic), and creating graphics. Consult the Help systems for the respective KMC tool for more information.

MS/TP NETWORK ACCESS PORT

The MS/TP EIA-485 data port on the bottom of the cover provides temporary access to an MS/TP network (not Ethernet) using devices like the HPO-5551, BAC-5051E, and KMC Connect. Refer to their documentation for details.

Illustration 14 - MS/TP (EIA-485) Data Port: Shows the location of the MS/TP data port on the bottom of the FlexStat cover.

MAINTENANCE

To maintain accurate temperature and humidity sensing, remove dust from ventilation holes in the top and bottom of the case as needed.

To maintain motion sensor sensitivity, occasionally wipe dust or dirt off the lens; do not use fluid on the sensor.

To clean the case or display, use a soft, damp cloth (and mild soap if necessary).

ADDITIONAL RESOURCES

Latest support files are available on the KMC Controls web site (www.kmccontrols.com). Log in to view all available files.

See the BAC-190000 Series FlexStats Data Sheet for:

• Specifications
• Accessories and replacement parts

See the BAC-19xxxx FlexStat Sequence of Operation and Wiring Guide for:

• Sample wiring for applications
• Sequences of operation
• Input/output objects and connections

See the BAC-19xxxx FlexStat Application Guide for:

• Configuration of settings
• Passwords
• Communication options
• Display customization
• Wiring considerations
• CO2 and DCV information
• Restarting options
• Troubleshooting

For additional instructions on custom configuration and programming, see the Help system in the relevant KMC software tool.

IMPORTANT NOTICES

NOTE: This device complies with Part 15 of the FCC Rules. Operation is subject to two conditions: (1) it may not cause harmful interference, and (2) it must accept any interference received, including interference that may cause undesired operation. This BAC-19xxxx Class A digital apparatus complies with Canadian ICES-003.

The material in this document is for informational purposes only. Contents and product descriptions are subject to change without notice.

KMC Controls, Inc. makes no representations or warranties regarding this document. KMC Controls, Inc. shall not be liable for any damages 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