KMC BAC-9000 Series VAV Controller Installation Guide

CONTENTS

• Introduction
• Set Drive Hub (45/60°) Rotation Limit
• Mount Controller
• Connect Sensors and Equipment
• Connect (Optional) Pressure Sensor
• Connect (Opt.) Ethernet Network
• Connect (Optional) MS/TP Network
• Connect Power
• Power and Communication Status
• MS/TP Network Isolation Bulbs
• Watch Dog Jumper
• Configure/Program the Controller
• Sample (BAC-9001) Wiring
• Input/Output Objects/Connections
• Replacement Parts
• Important Notices

INTRODUCTION

Complete the following steps to install a KMC Conquest™ BAC-9000 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 rotation 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. 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 [5] or 45 [6] stop hole position.
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.

Diagram Description (Page 1): Shows the controller board with numbered components. A hand is depicted pushing a gear release [1] and rotating the drive hub and V-clamp [2] to the left. It notes that the V-clamp nuts [3] should be on top. Another view shows the stop screw [4] in its storage location.

Diagram Description (Page 2): Illustrates inserting the stop screw into the 60 [5] or 45 [6] hole position. It also shows the VAV box damper shaft [7] and the gear disengagement lever [8] on the controller side. The drive hub and V-clamp [9] are shown being rotated.

MOUNT CONTROLLER

NOTE: Install the controller in a metal enclosure for RF shielding and physical protection.

NOTE: The controller can be installed on a 3/8–5/8 inch (9.5–16 mm) round or 3/8–7/16 inch (9.5–11 mm) square damper shaft with a minimum length of 2 inches (51 mm).

1. Manually rotate the damper shaft [7] on the VAV box to fully open the damper.
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.

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.
6. Center the mounting bushing [12] in the mounting tab [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 30–35 in-lb.

Diagram Description (Page 3): Shows the controller being mounted, with the mounting bushing [12] centered in the mounting tab [13]. The controller is attached with a screw. The V-clamp nuts [11] are shown being tightened.

CONNECT SENSORS AND EQUIPMENT

NOTE: For more information, see Sample (BAC-9001) 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 controller's (yellow [22]) ROOM SENSOR [15] port.
2. Connect auxiliary VAV equipment to the input and output green terminal blocks [17]. See Sample (BAC-9001) Wiring on page 8.

   CAUTION: Do NOT connect 24 VAC to the analog outputs (UO3–UO5 and GNDs)!

   NOTE: Use 24 VAC (only) with triac outputs (BO6–BO9 with SC).

Diagram Description (Page 3): Shows an Ethernet patch cable [14] being plugged into the Room Sensor port [15] on the controller. It also shows auxiliary VAV equipment connected to green terminal blocks [17].

CAUTION Box (Page 3): 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 (Page 3): The Ethernet patch cable should be a maximum of 150 feet (45 meters).

NOTE: Auxiliary VAV equipment such as fans, heaters, reheat valves, and discharge air temperature sensors can be connected to the controller.

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.

Diagram Description (Page 4): Shows the pressure sensor ports on the controller. The HIGH [18] and LOW [19] ports are indicated. Black shipping plugs [16] are shown removed.

NOTE (Page 4): Wire sizes 12–24 AWG can be clamped in each terminal. No more than two (16 AWG) wires can be joined at a common point.

CONNECT (OPT.) ETHERNET NETWORK

NOTE: Before May 2016, BAC-9001CE models had a single Ethernet port [20]. They now have dual Ethernet ports [21], enabling daisy-chaining of controllers. See the Daisy-Chaining Conquest Ethernet Controllers Technical Bulletin for more information.

1. For a BAC-9001CE (only), connect an Ethernet patch cable [20] to the 10/100 ETHERNET port [21].

CAUTION Box (Page 4): 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.

Diagram Description (Page 4): Shows the dual Ethernet ports [20, 21] on the controller, labeled "10/100 ETHERNET".

NOTE (Page 5): Also on the newer models, the Room Sensor port is yellow [22] instead of black to help differentiate it from the black Ethernet ports.

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

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 principles and good practices when connecting an MS/TP network, see Planning BACnet Networks (Application Note AN0404A).

1. For a BAC-9001 or BAC-9021, connect the network to the gray BACnet MS/TP network terminal block [23].
   • 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 KMC BACnet controllers.
2. Connect the cable shield to a good earth ground at one end only.

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).

Diagram Description (Page 5): Shows the MS/TP terminal block [23] and the EOL switch [24].

NOTE: The EOL switch is shipped from the factory in the OFF position.

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 (BAC-9001) Wiring on page 8 and the BAC-9000 series videos in the KMC Conquest Controller Wiring playlist.

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.
   • Connect the neutral side of the transformer to the controller's common terminal [26].
   • Connect the AC phase side of the transformer to the controller's phase terminal [27].

Diagram Description (Page 5): Shows the black power terminal block [25] with terminals for phase [27] and neutral/common [26].

NOTE: Connect only one controller to each transformer with 12–24 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 (BAC-9001) Wiring on page 8 and the BAC-9000 series videos in the KMC Conquest Controller Wiring playlist.

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).

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.

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.

Diagram Description (Page 6): Shows the controller with status LEDs: Green READY [28], Amber COMM [29], Green ETHERNET [30], and Amber ETHERNET [31].

MS/TP NETWORK ISOLATION BULBS

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.

Diagram Description (Page 6): Shows the MS/TP network isolation bulbs [32] on the controller board.

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).

Diagram Description (Page 7): Shows the location of the watch dog jumper [33] on the controller board.

CONFIGURE/PROGRAM THE CONTROLLER

See the table below 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-9001CE 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.

*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 Conquest 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.

SAMPLE (BAC-9001) WIRING

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

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.

Diagram Description (Page 8): This is a detailed wiring diagram for the BAC-9001 Controller. It shows connections for:

• From Previous Controller: MS/TP network connections (–A, +B, S for shield).
• To Next Controller: MS/TP network connections.
• Sensors: STE-9521, STE-6010-10 connected to Room Sensor port. STE-1405 Thermistor.
• Ethernet: Connection to 10/100 ETHERNET port.
• Controller Terminals: UI3-UI6, UO3-UO5, BO6-BO9, MS/TP block, Power terminals (24 VAC, Phase, Neutral), Pressure Sensor ports (HIGH/LOW).
• Outputs: Floating Reheat, Fan Start, COM, OPEN, CLOSE, COM, Fan Speed.

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, 0–12 VDC, or 4–20 mA.

NOTE: Use 24 VAC (only) on triac outputs (BO6–BO9 with SC)!

CAUTION: Do NOT connect 24 VAC to the analog outputs (UO3–UO5 and GNDs)!

INPUT/OUTPUT OBJECTS/CONNECTIONS

BAC-9001 SINGLE DUCT

*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

*See NOTE ABOUT REHEAT above.

NOTE: For more information, see Sample (BAC-9001) 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.

REPLACEMENT PARTS

HPO-0055: Replacement Network Bulb Module for Conquest Controllers, Pack of 5

HPO-9901: Conquest Hardware Replacement Parts Kit

NOTE: HPO-9901 includes the following:

• Terminal Blocks: (1) Black 2 Position, (2) Grey 3 Position, (2) Green 3 Position, (4) Green 4 Position, (2) Green 5 Position, (2) Green 6 Position
• DIN Clips: (2) Small, (1) Large

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 Lite™ 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

© 2022 KMC Controls, Inc. Specifications and design subject to change without notice.