KMC Controls BAC-4000 series User guide

Installation, Operation, and Application Guide
for
AppStat™
BAC-4000 series controllers for
Fan Coil Units, Roof Top Units, and Heat Pump Units.
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©2014, KMC Controls, Inc.
NetSensor, WinControl, and the KMC logo are registered trademarks of KMC
Controls, Inc.
AppStat, BACstage, FlexStat, FullBAC, TotalControl, SimplyVAV, and the
SimplyVAV logo are trademarks of KMC Controls, Inc.
All rights reserved. No part of this publication may be reproduced,
transmitted, transcribed, stored in a retrieval system, or translated into any
language in any form by any means without the written permission of KMC
Controls, Inc.
Printed in U.S.A.
The material in this manual 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
manual. 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 manual.
KMC Controls, Inc.
19476 Industrial Drive
New Paris, IN 46553
U.S.A.
TEL: [phone]
FAX: [phone]
E-mail: [e-mail]
Installation, Operation, and Application Guide for AppStat
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C o n t e n t s
Contents 3
Section 1: Introduction to the AppStat 7
Specifications 8
Installation accessories 12
AppStat model numbers 13
Safety considerations 16
Section 2: Installing the AppStat 17
Planning for motion sensing 17
Mounting the AppStat 18
Rough-in preparation 19
Installing the AppStat 19
Connecting inputs 20
Remote space temperature sensor (optional) 20
Discharge air temperature sensor 21
Fan status switch (optional) 21
Water temperature sensor 22
Outside air temperature 23
Connecting outputs 24
Connecting to a three-speed fan 24
Connecting to a modulating fan 25
Connecting on/off valves 26
Connecting to modulating valves 27
Connecting an economizer 28
Connecting power 28
Maintenance 29
Section 3: User functions 31
Operating the AppStat 31
Entering a user password 34
Changing the active setpoints 35
Setting the operating modes 36
Section 4: Commissioning functions 39
Enter the commissioning mode 40
Setting the commissioning setpoints 41
Set up communications 43
Set the time and date 45
Setting the occupancy schedule 47
Set fan coil unit system options 50
Set roof top unit system options 53
Set heat pump unit system options 56
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Advanced options 60
Section 5: Sequences of operation 65
Room temperature setpoints 66
Types of setpoints 66
Setpoint limits 67
Occupancy, motion sensing, and standby 67
Automatic cooling and heating changeover 68
Scheduling occupancy 68
Dehumidification sequence 68
Fan status 68
Display blanking and backlight 69
Temperature sensing inputs 69
Space temperature sensing 69
Outside air temperature sensing 69
Water temperature sensor 69
Discharge air temperature sensor 70
PID control loops 70
Valve operation for fan coil units 70
On/Off valves 70
Modulating valves 71
Two-pipe water supply temperature evaluation 71
Electric heat for fan coil units 72
Fan operation for fan coil units 72
One, two, and three speed fans 72
Modulating fans 72
Automatic fan control 73
Modulating cooling and heating for Roof Top Units 73
Cooling 73
Heating 73
Valve action 73
Staged heating and cooling for for roof top and heat pump units 74
Staged cooling 74
Staged heating 74
Fan control for roof top and heat pump units 74
Economizer cooling for roof top and heat pump units 75
Heat pump unit specific functions 75
Reversing valve action 75
Auxiliary or emergency heat action 75
Section 6: Application drawings 77
Fan Coil Unit applications 78
Fan Coil Unit—Four-pipe with three-speed fan and on/off valves 78
Fan Coil Unit—Four-pipe with three-speed fan and modulating valves 80
Fan Coil Unit—Four-pipe with modulating fan and on/off valves 82
Fan Coil Unit—Four-pipe with modulating fan and modulating valves 84
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Fan Coil Unit—Two-pipe with three-speed fan and on/off valves 86
Fan Coil Unit—Two-pipe with three-speed fan and modulating valve 88
Fan Coil Unit—Two-pipe with modulating fan and on/off valve 90
Fan Coil Unit—Two-pipe with modulating fan and modulating valve 92
Fan Coil Unit—Two-pipe with three-speed fan, modulating valve, and electric heat 94
Fan Coil Unit—Two-pipe with modulating speed fan, modulating valve, and electric heat 96
Roof Top Unit applications 98
Roof Top Unit—Two-stage gas heat and two-stage DX cooling 98
Roof Top Unit—Two-stage gas heat and two-stage DX cooling with economizer 100
Roof top unit—Cooling and heating with modulating valves and economizer 102
Roof Top Unit—Two-stage gas heat, chilled water cooling with modulating valve and
economizer 104
Roof Top Unit—Two-stage DX cooling, hot water heating with economizer 106
Heat Pump Unit applications 108
Heat pump unit—Three heat, two cool 108
Heat Pump Unit—Three heat, two cool and economizer 110
Section 7: System integration 113
BACnet objects 114
Input objects 114
Output objects 115
Value objects 117
Schedule object 119
Loop objects 119
Connecting to an MS/TP network 121
Index 125
Installation, Operation, and Application Guide for AppStat Contents
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Contents KMC Controls, Inc.
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Se c tio n 1: In tr o du c tio n to th e A ppStat
This section provides a description of the BAC-4000 series of controllers
KMC Controls, Inc.. It also introduces safety information. Review this
material before installing or operating the controllers.
The BAC-4000 series of controllers are space mounted devices that combine a
BACnet controller with temperature, humidity and motion sensors. The
controllers include programs for the following applications.
Roof top units, both single or multi-stage, or similar split or unitary
packaged systems
Heat pumps
Two and four pipe fan coil units
The AppStat controllers are native BACnet, Application Specific Controllers.
BACnet communication parameters, device instance, MAC address, baud rate,
room occupant adjustments, and application configuration values are set from
password protected front panel controls.
All models feature an integrated BACnet schedule and hardware real-time
clock with 72-hour capacitor backup for standalone operation or network
time synchronization.
A two-piece mechanical design, featuring a removable backplate, facilitates
easy wiring and installation.
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Specifications AppStat specifications are subject to change without notice.
User Interface
The user interface is a color display and with five push buttons. Through the
menu driven display, an operator can do the following.
Add or change user passwords
Change setpoints
Set BACnet addressing
Set up and commission the installation
Configure any available options
Security
Separate passwords for users and controls technicians.
Display type
128 × 128 pixels
Active color LCD with LED back lighting
1.00 x 1.04 inches (25 x 26 mm)
Inputs and outputs
All inputs and outputs are preprogrammed and application specific. No field
configuration is required for most installations. For details on input and
output connections see the section Application drawings on page 77.
Analog inputs
Analog inputs represent BACnet analog input objects and are configured
for discharge air temperature, remote temperature sensor, water
temperature sensor, and fan status. Not all input sensors are applicable or
required for all models.
Sensors are automatically detected.
Inputs accept industry-standard 10,000 Ω, Type II or Type III thermistors
sensors.
Input overvoltage protection up to 24 volts AC, continuous.
12-bit analog-to-digital conversion
Analog outputs
Analog outputs are configured to represent BACnet analog objects. The
outputs control modulating valves, variable speed fans, damper positions
or other equipment that requires a proportional input signal.
Section 1: Introduction to the AppStat KMC Controls, Inc.
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Short-circuit protected
Loads up to 10 mA at 0–12 volts DC
8-bit PWM digital-to-analog conversion
Relay outputs
Relay outputs are configured to represent BACnet binary objects. The
outputs control on/off valves, speeds for three-speed fans, fan start circuits,
or other equipment that requires an on or off input signal.
All relay outputs are normally open, SPST, Form “A” relays
1 Ampere maximum per relay at 24 volts AC or DC for each output.
Maximum for all relay outputs is 3 amperes (72VA).
Connectors
Screw terminal block mounted to backplate
Wire size 14-22 AWG
Communications—BACnet MS/TP
Integral peer-to-peer BACnet MS/TP network communications.
Network speeds from 9600 to 76,800 baud.
Front panel configurable device instance, MAC address, and baud.
Automatic baud detection.
Screw terminal block mounted to backplate. Wire size 14–22 AWG
Meets or exceeds ANSI/ASHRAE BACnet Standard 135-2008 for
Application Specific Controllers
Accuracy–temperature only models
Type Thermistor
Accuracy ±0.36° F (±0.2° C)
Resistance 10,000 Ω at 77° F (25° C)
Operating range 48 to 96° F (8.8 to 35.5° C)
Accuracy–temperature and humidity models
Temperature Sensor
Type CMOS
Accuracy ±0.9° F offset (±0.5° C) from 40° to 104° F
(4.4 to 40° C)
Resolution ±0.1°F (±0.1° C)
Operating range 36 to 120° F (2.2 to 48.8° C)
Response time 5 to 30 seconds
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Humidity Sensor
Type CMOS
Humidity 0 to 100% RH
Accuracy at 25° C ± 2% RH from 10 to 90% RH
Response time 4 seconds or less
Regulatory
UL 916 Energy Management Equipment
FCC Class A, Part 15, Subpart B and complies with Canadian ICES-003
Class B
BACnet Testing Laboratory listed as an application specific controller
SASO PCP Registration KSA R-103263
This device complies with part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) This device may not cause harmful interference,
and (2) this device must accept any interference received, including
interference that may cause undesired operation.
Environmental limits
Operating 32 to 120° F (0 to 49° C)
Shipping –40 to 140° F (–40 to 60° C)
Humidity 0–95% relative humidity
(non-condensing)
Installation
Supply voltage 24 volts AC (–15%, +20%), 50-60 Hz, 12 VA, Class 2
only, non-supervised.
All circuits, including supply voltage, are power
limited circuits.
Weight Approximately 6 ounces (170 grams)
Case material Flame retardant plastic
Section 1: Introduction to the AppStat KMC Controls, Inc.
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Dimensions
A
B
C
A B C
3.50 in. 5.12 in. 1.12 in.
89 mm 130 mm 29 mm
Table 1–1 AppStat Dimensions
Motion sensor
Motion sensors are options available only on select models.
Detector type Passive infrared
Range 33 feet (10 meters). See the following
diagrams.
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10 m
32.8 ft
10 m
32.8 ft
0°
46.5°
Y
55°
10 m
32.8 ft
10 m
32.8 ft
X
0°
Side viewTop view
Installation
accessories
The following accessories are available from KMC Controls, Inc.
XEE-6111-040 Single-hub 120 volt power transformer
XEE-6112-040 Dual-hub 120 volt power transformer
XEE-6311-075 120/240/277/480VAC, 24 VAC, 75 VA transformer
HMO-10000W White mounting plate kit for retrofit on horizontal
boxes or 4 x 4 handy boxes
Section 1: Introduction to the AppStat KMC Controls, Inc.
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AppStat model
numbers
Use the following charts to identify features in a specific AppStat model.
Fan coil units—The model numbers for these controllers end with "0001".
The inputs, outputs, and sequences of operation are configured and
programmed for the following functions.
Two-pipe heating and cooling with on/off valves, modulating valves or
both
Four-pipe heating and cooling with on/off valves, modulating valves or
both
Three-speed or modulating fan control
Automatic or manual fan control
Remote space temperature sensor
Local temperature setback mode based on optional built-in motion
sensor
Dehumidification on models with humidity sensor
See the following chart for the specific features included with each model.
Illustration 1–1 Model numbers for fan coil units
BAC-4 _ _ _ CW0001
1 3-speed fan, On/off valves
2 3-speed fan, Modulating valves
3 3-speed or modulating fan,
modulating or On/Off valves
7 Modulating fan, On/Off valves
8 Modulating fan, Modulating Valves
0 Without humidity
2 With humidity
0 Without motion
2 With motion
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Roof top units—The model numbers for these controllers end with "0002".
These models control roof top or similar packaged or split unitary units. The
inputs, outputs, and sequences of operation are configured and programmed
for the following functions.
Automatic or manual fan control
Modulating valves or on/off heating and cooling valves.
One or two stage heating
One or two stage cooling
Optional economizer
Remote space temperature sensor
Local temperature setback mode based on optional built-in motion
sensor
Dehumidification on models with humidity sensor
See the following chart for the specific features included with each model.
Illustration 1–2 Model numbers for roof top units
BAC-4 _ _ _ CW0002
12H/2C On/off valves or stages
32H/2C On/off or modulating valves
and economizer
0 Without humidity
2 With humidity
0 Without motion
2 With motion
Heat pump units—The model numbers for these controllers end with "0003".
The inputs, outputs, and sequences of operation are configured and
programmed for the following functions.
Two stages of heat and two stages of cooling plus auxiliary heat
Optional economizer
Dehumidification-in models with auxiliary heat and a humidity sensor
Local temperature setback mode based on optional built-in motion
sensor
Automatic or manual fan control
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See the following chart for the specific features included with each model.
Illustration 1–3 Model numbers for heat pump units
BAC-4 _ _ _ CW0003
13H/2C
3 3H/2C and economizer
0 Without humidity
2 With humidity
0 Without motion
2 With motion
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Safety
considerations
KMC Controls, Inc. assumes the responsibility for providing you a safe
product and safety guidelines during its use. Safety means protection to all
individuals who install, operate, and service the equipment as well as
protection of the equipment itself. To promote safety, we use hazard alert
labeling in this manual. Follow the associated guidelines to avoid hazards.
Danger
Danger represents the most severe hazard alert. Bodily
harm or death will occur if danger guidelines are not
followed.
Warning
Warning represents hazards that could result in severe
injury or death.
Caution
Caution indicates potential personal injury, equipment
damage, or property damage if instructions are not followed.
Note: Notes provide additional information that is important.
Tip: Provides programing tips and shortcuts that may save time.
Section 1: Introduction to the AppStat KMC Controls, Inc.
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Se c t io n 2: In s tall in g th e A pp Stat
This section provides important instructions and guidelines for installing
the AppStat. Carefully review this information before installation begins.
Installing the sensors includes the following topics that are covered in this
section.
Planning for motion sensing on page 17
Mounting the AppStat on page 18
Connecting inputs on page 20
Connecting outputs on page 24
Connecting power on page 28
Maintenance on page 29
Planning for motion
sensing
For models with a motion sensor mount the AppStat on a wall that will have
an unobstructed view of the typical traffic in the coverage area. When
choosing a location, do not install the sensor in the following areas.
Behind curtains or other obstructions
In locations that will expose it to sunlight or heat sources
Near a heating or cooling inlet or outlet.
For details on the coverage pattern, see Specifications on page 8.
Illustration 2–1 Typical motion sensing coverage area
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The effective detection range is approximately 10 meters or 33 feet. Factors
that may reduce the range include:
The difference between the surface temperature of the object and the
background temperature of the room is too small.
Object movement in a direct line toward the sensor.
Very slow or very fast object movement.
Obstructions as shown in the illustration Typical motion sensing coverage
area on page 17.
False detections may be triggered by:
The temperature inside the detection range suddenly changes because of
the entry of cold or warm air from an air-conditioning or heating unit.
The sensor being directly exposed to sunlight, an incandescent light, or
other source of far-infrared rays.
Small animal movement.
Mounting the
AppStat
For the most accurate performance, install the AppStat on an inside wall
where it can sense the average room temperature. Avoid locations with direct
sunlight, heat sources, windows, air vents, and air circulation or obstructions
such as curtains, furniture, etc.
The AppStat must not be:
Mounted on an exterior wall.
Mounted on or near an object with large a thermal mass such as a
concrete block wall.
Blocked from normal air circulation by obstructions.
Exposed to heat sources such as lights, computers, copiers, or coffee
makers, or to direct sunlight at any time of the day.
Exposed to drafts from windows, diffusers, or returns.
Exposed to air flow through connecting conduits or empty spaces behind
walls.
For models with motion sensing, see the topic, Planning for motion sensing.
Section 2: Installing the AppStat KMC Controls, Inc.
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Rough-in preparation
Complete rough-in wiring at each location before mounting an AppStat. This
includes the following steps.
Install the supplied mounting base directly to a wall, a vertical electrical
box, or a box with a wall plate kit.
Routing the connecting cable or cables from the AppStat to the
equipment it is controlling.
If required, install an appropriate wall plate kit.
Block leaks and airflow from conduits with plumber’s putty or similar
material.
If replacing an existing thermostat, label existing wires for reference
when removing the existing thermostat.
Illustration 2–2 AppStat mounting base details
A
5.12 in.
130 mm
3.50 in.
89 mm
Inputs and
network
Power and outputs
Installing the AppStat
To install the controller on a mounting base, do the following:
1. Turn the Allen screw in the base of the sensor clockwise until it clears
the case.
Turn clockwise to remove
from base.
2. Swing the AppStat away from the mounting base to remove it.
3. Route wiring for the AppStat through the mounting base.
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4. Position the base with the embossed UP toward the ceiling and fasten it
directly to a vertical 2x4 inch electrical box. For horizontal boxes or
4x4 applications, use a wall plate kit. See Installation accessories on page
12 for part numbers.
5. Connect the wires for the AppStat to the terminals in the mounting base.
6. Place the top of the sensor over the top of the mounting base and swing
it down over the Allen screw bracket. Be careful not to pinch any wiring.
7. Turn the Allen screw counterclockwise until it backs out of the mounting
base and engages the case.
Turn counterclockwise
until the screw engages
the base.
Caution
To prevent mounting screw heads from touching the circuit
board in the controller, use only the mounting screws
supplied with the controller. Using screws other than the
type supplied may damage the AppStat.
Connecting inputs The inputs for the AppStat are configured for specific functions and do not
require set up in the field. Not all inputs are required for every model or
application. See the topic BACnet objects on page 114 for the configuration
properties of the input objects.
Remote space temperature sensor (optional)
Connect a 10kΩ, TypeII thermistor temperature sensor to the remote space
temperature (RS) input and ground (GND) terminals. The input includes the
internal pull-up resistor. An STE-6011W10 sensor is suitable for this
application. Follow the instructions supplied with the sensor for installation.
When a remote space temperature input is connected to the AppStat, the
remote temperature is used instead of the internal temperature sensor.
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