Manuals+

KMC Controls Airflow Measurement System Installation Guide (Gen5)

Contents

This document outlines the installation procedures for the KMC Controls Airflow Measurement System (Gen5). It covers component mounting, wiring, network connections, and configuration.

Example Diagrams

Standard Application

This section details the standard application of the Airflow Measurement System, illustrating the typical setup and component placement within an HVAC unit.

A diagram shows the system components including an OAT Sensor (STE-1404/05/12), Inclinometer, Proportional Actuator (MEP-4522/4952/7552), STE-1412/13/14 sensors, SSS-1xXX Series Pickup Tubes, TPE-1475-21/22 Pressure Transducer, RAT Sensor (STE-1404/05), and AFMS Controller (TRF-5901C(E)-AFMS or TRF-9311C(E)-AFMS).

Outdoor Air Damper Pressure Assist Application

This section describes the setup for an Outdoor Air Damper (OAD) pressure assist application. It shows the placement of sensors and the controller for this specific configuration.

A diagram illustrates the system with an OAT Sensor, Inclinometer, Proportional Actuator, STE-1412/13/14 sensors, SSS-1xXX Series Pickup Tubes, TPE-1475-21 Pressure Assist Transducer, RAT Sensor, and AFMS Controller.

Return Air Damper Pressure Assist Application

This section details the installation for a Return Air Damper (RAD) pressure assist application, highlighting the component arrangement for this scenario.

A diagram shows the system with an Inclinometer, Proportional Actuator, RAT Sensor, SSS-1xXX Series Pickup Tubes, TPE-1475-21 Pressure Assist Transducer, MAT Sensor, and AFMS Controller.

Mounting the System Components

Mounting the Controller

The controller should be mounted inside a metal enclosure for RF shielding and physical protection. Mounting can be done on a flat surface or a 35 mm DIN rail.

On a Flat Surface

  1. Position the controller for easy access to terminal blocks.
  2. Secure the controller using four #6 sheet metal screws through the corner mounting holes.

On a DIN Rail

  1. Position the DIN rail for easy access to terminal blocks.
  2. Pull out the DIN latch until it clicks.
  3. Rest the controller's top tabs on the DIN rail.
  4. Lower the controller onto the rail.
  5. Push in the DIN latch to secure it.

Mounting the Inclinometer

If the outside air damper has vertical-axis blades, install an HLO-1050 Linkage Kit first. Then, mount the inclinometer on a horizontal-axis damper blade (preferably outside air, or return air if multiple return dampers exist) with the wire parallel to the blades and the arrow pointing up. Secure with two #8 sheet metal screws. Route the wire to avoid binding the damper and ensure strain relief.

Mounting the Supply Airflow Pickup Tubes

Multiple pickup tubes (at least 2) are recommended for accurate average readings. They can be installed in the Supply Air Fan Bell (using SSS-1112/3/4 or SSS-1115/6/7) or in the Supply Air Duct (using SSS-101x).

On the Supply Air Fan Bell (using SSS-1112/3/4)

  1. Position the pickup tubes' mounting foot on the fan bell edge, pointing towards the fan inlet center. Ensure all pickup points are in the airstream.
  2. Attach tubes using two self-tapping screws through the 3/16" mounting holes.
  3. Repeat for remaining tubes.

On the Supply Air Fan Bell (using SSS-1115/6/7)

  1. Position pickup tubes so mounting feet span the fan inlet, with all pickup points in the airstream.
  2. Attach the first mounting foot with two self-tapping screws through the 3/16" mounting holes.
  3. Attach the second mounting foot to the opposite edge or strut with two self-tapping screws.
  4. Repeat for remaining tubes.

In the Supply Air Duct (using SSS-101x)

Mount pickup tubes in filtered air with laminar flow, approximately 6 straight duct diameters downstream. Ensure the FLOW arrow imprint is in the direction of airflow.

  1. Determine duct flow direction and install pickup tubes according to the flow arrow.
  2. Cut a 7/8" hole in the duct for the tubes.
  3. Attach tubes to the duct using two self-tapping screws through the 3/16" mounting holes.
  4. Repeat for remaining tubes.

Mounting Pickup Tubes for Pressure Assist

Mounting for OAD Pressure Assist

For OAD pressure assist applications, install two additional SSS-1000 series pickup tubes.

Mounting the First Pickup Tube
  1. Locate the first pickup tube outside the OAD, in a non-turbulent flow area (e.g., under the air intake hood).
  2. Install the tube so the FLOW arrow is perpendicular to airflow (for static pressure). The arrow can point up or down. Mark the tube for orientation.
  3. Cut a 7/8" (22 mm) hole in the duct.
  4. Attach the tube using two self-tapping screws through the 3/16" (5 mm) mounting holes.
Mounting the Second Pickup Tube
  1. Locate the second pickup tube in the mixed air chamber, in a non-turbulent flow area.
  2. Install the tube so the FLOW arrow is perpendicular to airflow. The arrow can point up or down. Mark the tube for orientation.
  3. Cut a 7/8" (22 mm) hole in the duct.
  4. Attach the tube using two self-tapping screws through the 3/16" (5 mm) mounting holes.

Mounting for RAD Pressure Assist

For RAD pressure assist applications, install two additional SSS-1000 series pickup tubes.

Mounting the First Airflow Pickup Tube
  1. Locate the first pickup tube upstream of the return air damper.
  2. Install the tube so the FLOW arrow is perpendicular to airflow. The arrow can point up/down or left/right depending on duct orientation. Mark the tube for orientation.
  3. Cut a 7/8" (22 mm) hole in the duct.
  4. Attach the tube using two self-tapping screws through the 3/16" (5 mm) mounting holes.
Mounting the Second Airflow Pickup Tube
  1. Locate the second pickup tube downstream of the return air damper (in the mixed air side).
  2. Install the tube so the FLOW arrow is perpendicular to airflow. The arrow can point up/down or left/right depending on duct orientation. Mark the tube for orientation.
  3. Cut a 7/8" (22 mm) hole in the duct.
  4. Attach the tube using two self-tapping screws through the 3/16" (5 mm) mounting holes.

Mounting the Pressure Transducer(s)

For TRF-5901C(E)-AFMS controllers, mount the pressure transducer(s) near the airflow pickup tubes, avoiding locations with severe vibrations or excessive moisture. Use screws through the mounting holes. If using additional pickup tubes for pressure assist, mount a second transducer near those tubes.

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.

Mounting the OAT, RAT, and MAT Sensors

STE-1411/12/13/14 Bendable Copper Sensor

Use for easily-accessible mixed air sections and outside air hoods. For less accessible sections, a flexible cable sensor may be used. For units without an accessible outside air hood, a rigid steel probe can be used.

  1. Cut a hole in the mixed air chamber for the copper probe.
  2. Insert the sensor probe, bend it to cover the air path, and secure it. Maintain a minimum bend radius of six inches.
  3. Fasten the enclosure to the unit using screws through the mounting holes.
  4. Attach conduit to the 1/2" NPT threaded connection hole at the bottom of the enclosure for the cable to the controller.
  5. Open the cover by pulling the latch and the cover.

STE-1415/6/7 Flexible Cable Sensor

Use if the mixed air section is not easily accessible. String the cable to cover the air path and secure it, observing a minimum bend radius of two inches.

  1. Cut a hole in the mixed air chamber for the sensor cable.
  2. Insert the sensor cable, string it to cover the air path, and secure as needed.
  3. Fasten the enclosure to the unit using screws through the mounting holes.
  4. Attach conduit to the 1/2" NPT threaded connection hole at the bottom of the enclosure for the cable to the controller.
  5. Open the cover by pulling the latch and the cover.

STE-1404/05 Rigid Steel Probe

Use for the return air duct or for the outside air duct if the unit lacks an easily accessible outside air hood. Locate the sensor in a straight section of duct, away from heat, cooling, or humidifier sources.

  1. Cut a 1/4-inch hole for the probe and smaller holes for screws.
  2. Insert the probe and fasten the assembly to the duct using screws.
  3. Open the sensor cover (STE-1404 only) by pulling the latch and the cover.
  4. Attach conduit to the 1/2" NPT threaded connection hole at the bottom of the enclosure for the cable to the controller.

Mounting a Proportional Actuator

Mount a proportional actuator on the appropriate damper (outside air for standard/OAD pressure assist, return air for RAD pressure assist) if one is not already installed. Refer to the specific model's installation guide (MEP-4552, MEP-4952, MEP-7552) for detailed mounting instructions.

Connecting System Components to the Controller

Connecting the Airflow Pickup Tubes

For a TRF-5901C(E)-AFMS

Use appropriately sized polyethylene tubing. Keep tubing runs as short as possible and arrange to prevent stress or kinking.

Connecting the Supply Airflow Pickup Tubes to the Pressure Transducer
  1. Connect the Port H of all pickup tubes in parallel to the High input on the supply air pressure transducer.
  2. Connect the Port L of all pickup tubes in parallel to the Low input on the supply air pressure transducer.
Connecting the Airflow Pickup Tubes for OAD Pressure Assist Applications
  1. Connect one port of the pickup tube mounted outside the OAD to the High input of the pressure assist transducer.
  2. Connect one port of the pickup tube mounted inside the OAD to the Low input of the pressure assist transducer.
  3. The other ports remain unconnected and open to air.
Connecting the Airflow Pickup Tubes for RAD Pressure Assist Applications
  1. Connect one port of the pickup tube mounted upstream of the return air damper to the High input of the pressure assist transducer.
  2. Connect one port of the pickup tube mounted downstream of the return air damper to the Low input of the pressure assist transducer.
  3. The other ports remain unconnected and open to air.

Connecting the Pressure Transducer(s) to the Controller

For a TRF-5901C(E)-AFMS

  1. Connect the signal wire from the supply air pressure transducer's OUT terminal to UI9 on the controller.
  2. If a second transducer is used for pressure assist, connect its signal wire from OUT to UI10 on the controller.

For a TRF-9311C(E)-AFMS

Use 1/4 inch (6.35 mm) FR tubing, not exceeding 20 feet (6 meters).

  1. Remove black shipping plugs from the PRESSURE SENSOR ports.
  2. Connect the Port H of all pickup tubes in parallel to the HIGH port on the controller.
  3. Connect the Port L of all pickup tubes in parallel to the LOW port on the controller.

Connecting the Inclinometer

  1. Connect the yellow signal wire to UI7 on the controller.
  2. Connect the green signal wire to UI8 on the controller.
  3. Connect the blue ground wire to GND (between UI7 and UI8) on the controller.
  4. Connect the red power wire to UO8 (TRF-5901C[E]-AFMS) or U10 (TRF-9311C[E]-AFMS).

Connecting the Outside Air Temperature Sensor

Use 18 to 24 AWG shielded wiring. Avoid running device wires in the same conduit as inductive loads.

  1. Feed the wire to the controller through the bottom hole.
  2. Make connections using butt-splices or solder.
  3. Plug the conduit with sealant.
  4. Close the door securely.
  5. Install provided screws in the door's screw tabs for added security.
  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

Use 18 to 24 AWG shielded wiring. Avoid running device wires in the same conduit as inductive loads.

  1. Feed the wire to the controller through the bottom hole (if applicable).
  2. Make connections using butt-splices or solder.
  3. Plug the conduit with sealant (if applicable).
  4. Close the door securely (if applicable).
  5. Install provided screws in the door's screw tabs for added security (if applicable).
  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

Use 18 to 24 AWG shielded wiring. Avoid running device wires in the same conduit as inductive loads.

  1. Feed the wire to the controller through the bottom hole.
  2. Make connections using butt-splices or solder.
  3. Plug the conduit with sealant.
  4. Close the door securely.
  5. Install provided screws in the door's screw tabs for added security.
  6. Connect the sensor's signal wire to UI6 on the controller.
  7. Connect the sensor's ground wire to GND (next to UI6) on the controller.

Connecting the Proportional Actuator

Using an Existing Proportional Actuator

CAUTION: Power off the actuator and the other controller before proceeding.

  1. Disconnect the signal and ground wires from the existing actuator.
  2. Connect the existing signal wire to UI3 on the AFMS controller.
  3. Connect the existing ground wire to the GND terminal (next to UI3) on the AFMS controller.
  4. Run a new signal wire from UO7 (TRF-5901-AFMS) or UO9 (TRF-9311-AFMS) to the actuator's signal terminal.
  5. Connect the signal common wire of the new wire to the GND terminal (next to UO7/UO9) on the AFMS controller.

Using a New Proportional Actuator

Refer to the specific model's installation guide (MEP-4552, MEP-4952, MEP-7552) for detailed wiring instructions to the controller. Consult the Wiring Diagrams and Input/Output Objects/Connections sections for specific terminal information.

Connecting Networks

Connecting an Ethernet Network

For "E" models, connect an Ethernet patch cable to the 10/100 ETHERNET port. Use T568B Category 5 or better cable, with a maximum length of 328 feet (100 meters).

CAUTION

Do NOT plug a cable meant for Ethernet communications into the Room Sensor port, as the voltage may damage an Ethernet switch or router.

Default network addresses for Ethernet models are: IP address - 192.168.1.251, Subnet mask - 255.255.255.0, Gateway - 192.168.1.1.

Connecting an MS/TP Network

For TRF-5901C-AFMS or TRF-9311C-AFMS, connect the BACnet network to the gray BACnet MS/TP terminal block using 18 AWG shielded twisted pair cable.

  1. Connect the -A terminals in parallel with other -A terminals on the network.
  2. Connect the +B terminals in parallel with other +B terminals on the network.
  3. Connect cable shields together at each device using a wire nut or the S terminal.
  4. Connect the cable shield to earth ground at one end only.
  5. If the controller is at either end of the network, turn the EOL switch to ON.

Connecting Power

Connecting Power to the Controller

Connect a 24 VAC, Class-2 transformer to the controller's black power terminal block.

  1. Connect the neutral side of the transformer to the controller's common terminal (⊥).
  2. Connect the AC phase side of the transformer to the controller's phase terminal (~).

NOTE: Connect only one controller per transformer. Use 12–24 AWG copper wire. Use shielded cables or enclose cables in conduit for RF emissions compliance.

For DC power, refer to the KMC Conquest Controller Application Guide.

Connecting Power to the Inclinometer

  1. Connect the inclinometer's red power wire to UO8 (TRF-5901-AFMS) or UO10 (TRF-9311-AFMS).
  2. Connect the inclinometer's blue ground wire to GND/SC on the controller.

Connecting Power to the Pressure Transducer(s)

For TRF-5901C(E)-AFMS controllers:

Use at least 22 AWG, shielded, twisted-pair wiring. Do not run device wires in the same conduit as inductive loads.

CAUTION

Ensure the circuit ground point is the same on all devices and the controller when grounding the transformer secondary or wiring multiple devices.

  1. Connect the controller's phase terminal (~) to the transducer's PWR terminal.
  2. Connect the controller's common terminal (⊥) to the transducer's COM terminal.
  3. If a second transducer is used, repeat steps 1 and 2.

Connecting Power to the Proportional Actuator

Refer to the specific model's installation guide (MEP-4552, MEP-4952, MEP-7552) for detailed instructions on wiring to power and completing setup.

Controller Power and Communication Status

Status LEDs on the TRF-5901-AFMS and TRF-9311-AFMS indicate power and network communication.

Green READY LED

Flashes approximately once per second after power-up, indicating normal operation.

Amber (BACnet MS/TP) COMM LED

Flickers during normal operation as the token is passed. Flashes about once per second if the network is not connected or communicating properly.

Green ETHERNET LED

Stays ON when the controller is communicating with the network. OFF when not communicating.

Amber ETHERNET LED

Flashes when communicating at 100BaseT. OFF when communicating at 10 Mbps.

Controller MS/TP Network Isolation Bulbs

The two network isolation bulbs (HPO-0055) isolate the controller when removed. If bulbs are ON, the network is improperly phased. If bulbs blow, the network voltage or current exceeds safe levels.

Wiring Diagrams

TRUEFIT Airflow Measurement System Model: TRF-5901C(E)-AFMS

Diagrams illustrate inclinometer mounting, supply air flow measurement, and overall system wiring, including connections to OAT, OAD, RAT, MAT sensors, pressure transducers, and the controller.

Notes:

TRUEFIT Airflow Measurement System Model: TRF-5901C(E)

Diagrams show the system components and their interconnections.

TRUEFIT Airflow Measurement System with Pressure Assist Model: TRF-5901C(E)-AFMS

Diagrams detail inclinometer mounting and airflow measurement for pressure assist applications, including connections to OAD, RAD, and associated sensors and transducers.

Notes:

TAUeFIT Airflow Measurement System Model: TRF-9311C(E)

Diagrams illustrate system connections for the TRF-9311C(E) model.

Notes:

TrueFIT Airflow Measurement System Model: TRF-9311C(E)

Diagrams show system connections for the TRF-9311C(E) model.

Input/Output Objects/Connections

TRF-5901C(E)-AFMS

Inputs
AI1Space Sensor (on Room Sensor port)
AI2Space Setpoint Offset (on port)
AI3/UI3Incoming Damper Signal
AI4/UI4Outdoor Air Temp
AI5/UI5Return Air Temp
AI6/UI6Mixed Air Temp
AI7/UI7Inclinometer V1 (yellow wire)
AI8/UI8Inclinometer V2 (green wire)
AI9/UI9Supply Air Pressure Transducer
AI10/UI10Additional Transducer (if pressure assist is needed)
Outputs
AO6/UO60-10 VDC CFM Output
AO7/UO7Outdoor Air Damper
AO8/UO8Inclinometer Power (red wire)
BO1Binary Output #1
BO2Binary Output #2
BO3Binary Output #3
BO4Binary Output #4
BO5Binary Output #5
Note: Connect inclinometer blue wire to a GND terminal.

TRF-9311C(E)-AFMS

Inputs
AI1Space Sensor (on Room Sensor port)
AI2Space Setpoint Offset (on port)
AI3/UI3Incoming Damper Signal
AI4/UI4Outdoor Air Temp
AI5/UI5Return Air Temp
AI6/UI6Mixed Air Temp
AI7/UI7Inclinometer V1 (yellow wire)
AI8/UI8Inclinometer V2 (green wire)
AI9Differential Pressure Sensor (integrated port)
Outputs
AO7/UO7Analog Output #7
AO8/UO80-10 VDC CFM Output
AO9/UO9Outdoor Air Damper
AO10/UO10Inclinometer Power (red wire)
BO1Binary Output #1
BO2Binary Output #2
BO3Binary Output #3
BO4Binary Output #4
BO5Binary Output #5
BO6Binary Output #6
Note: Connect inclinometer blue wire to a GND terminal.

Configuring and Operating

Configuration and operation of the AFMS can be performed using various tools. Refer to the documentation for each tool on its respective product page.

PROCESSESCONFIGURATION TOOLS
BAC-5051(A)E routerEthernet controller served web pagesConquest™ NetSensorKMC Connect™ or TotalControl™KMC Converge™ for Niagara WorkbenchKMC Commander®2KMC Connect Lite™ (NFC) app3
Selecting the application✓✓✓
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.

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Important Notices

The information in this document is for informational purposes only. The contents and the product described 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, 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 Lite™ app for NFC configuration is protected under United States Patent Number 10,006,654. Patents: https://www.kmccontrols.com/patents/

TEL: 574.831.5250

FAX: 574.831.5252

EMAIL: info@kmccontrols.com

Models: S92501907D, Gen5 Airflow Measurement System, Airflow Measurement System, Measurement System, System

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References

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