KMC Controls KMD-5205 Operating instructions

Installation and
Operation Guide
KMD-5205
LanLite Controller
KMD-5270
WebLite Controller
909-019-01JRevision J

KMC Controls
Revision J2
Important notices ©2013, KMC Controls, Inc.
WinControl, NetSensor, and the KMC logo are registered trademarks of KMC Controls,
Inc.
TotalControl, BACstage, and FullBAC 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.
Disclaimer 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
P.O. Box 497
19476 Industrial Drive
New Paris, IN 46553
U.S.A.
TEL: [phone]
FAX: [phone]
E-mail: [email protected]

KMD-5205 and KMD-5270 Installation and Operation
Revision J 3
Contents
Section 1
About the controllers
Introduction .......................................................................................................................... 5
Internet operation ................................................................................................................ 5
BACnet 8802-3 option ......................................................................................................... 5
Modbus option ..................................................................................................................... 5
Specifications ........................................................................................................................ 6
Models and options ........................................................................................................... 10
Accessories and replacement parts ................................................................................. 10
Controls and connections ................................................................................................. 11
Safety considerations ........................................................................................................ 12
Section 2
Installing the controllers
Mounting ............................................................................................................................ 13
Connecting inputs ............................................................................................................. 13
Connecting outputs ........................................................................................................... 14
Connecting to networks .................................................................................................... 15
KMC Tier 1 networks ........................................................................................................ 15
KMC Tier 2 networks ........................................................................................................ 15
BACnet 8802-3 (optional) ................................................................................................. 17
Modbus (optional) ............................................................................................................. 18
Connecting power ............................................................................................................. 20
Connecting to a computer through the serial port ....................................................... 21
Connecting to a modem .................................................................................................... 22
Section 3
Operating the controller
Lights and indicators ......................................................................................................... 23
Powering the controller .................................................................................................... 24
Maintenance ....................................................................................................................... 24
Replacing the fuse .............................................................................................................. 24
Resetting the controller ..................................................................................................... 25
Section 4
Configuration and programming
Initializing with HCM ....................................................................................................... 27
Setting up for BACnet networks ..................................................................................... 30
Control Basic programming for BACnet ........................................................................ 31
Setting up for Modbus networks ..................................................................................... 32
Programming for Modbus in WinControl XL Plus ...................................................... 32
Firewalls and network communications ........................................................................ 33
System time keeping ......................................................................................................... 33
System graphics ................................................................................................................. 34

KMC Controls
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Section 5
Using a web browser (KMD-5270 models only)
Applicable models ............................................................................................................. 35
Browser requirements ....................................................................................................... 36
Opening the WebLite home page .................................................................................... 36
Viewing and editing .......................................................................................................... 38
PID controllers ................................................................................................................... 40
Trend Logs .......................................................................................................................... 40
Schedules ............................................................................................................................ 42

KMD-5205 and KMD-5270 Installation and Operation
Revision J 5
SECTION 1
About the controllers
This section provides a description and specifications—including the
BACnet and Modbus options—for models KMD-5205 LANLite and
KMD-5270 WebLite controllers. Safety information is included also.
Review this material before installing or operating the controllers.
Introduction The KMD-5205 and KMD-5270 both provide programmable control and
high-level LAN connectivity for facilities management systems. These powerful,
direct-digital-controllers operate on a peer-to-peer, token passing protocol, using
either Ethernet or EIA-485 networks.
◆Ethernet for KMD Tier 1 controllers and optional BACnet 8802.3 devices.
◆EIA-485 for either KMD Tier 2 or Modbus RTU controllers
The operating software in the controllers use a high level, easy to learn
programming language to ensure reliability, rapid programming and
compatibility with future KMC system enhancements.
Internet operation
KMD-5270 models only The embedded internet server in the KMD-5270 models make them ideal
controllers for schools and businesses with an Ethernet infrastructure. System
operation can be changed using a standard internet browser such as Netscape or
Microsoft® Internet Explorer. In addition to changing settings, you can view
system groups, trend and runtime logs with the browser.
BACnet 8802-3
option
Models with the BACnet option adds open-system functionality to these
controllers.
◆BACnet devices see input, output and variables in the controller as BACnet
input, output and value objects.
◆When installed on the same Ethernet broadcast domain segment as a
BACnet 8802-3 network, use Control Basic to retrieve data from any
accessible BACnet object on the internetwork.
Modbus option Connect directly to Modbus RTU equipment with the Modbus option. Modbus
registers are mapped to variables in the controller that are then available for use
by other KMD controllers, BACnet devices or Control Basic.

KMC Controls
Revision J
About the controllers
Specifications
6
Specifications Specifications for the KMD-5205 and KMD-5270 series of controllers are
subject to change without notice.
Inputs 8 universal inputs
Key features Software selectable for analog or digital signals.
Standard and custom units of measure.
Pull-up resistors for switch contacts and other
unpowered equipment.
Connector Removable screw terminal block, wire size
12–22 AWG
Conversion 12-bit analog–to–digital
Pulse Counting Up to 1000 Hz
Input impedance 100 kΩwithout pull-up resistors
Analog input range 0–5 volts DC, 4–20 milliamperes DC
Digital input range 0–5 volts DC and pulse counting
Pull-up resistors None, 1kΩand 10kΩselected with movable
jumper
Outputs 8 universal outputs
Key features Software programmable for analog or digital
signals. Standard and custom units of measure.
Slots for KMC output override boards
Connector Removable screw terminal block, wire size
12–22 AWG
Conversion 12-bit digital-to-analog
Analog output range 0–10 volts DC, 50 milliamperes maximum
Programmable features
Control Basic programs 10 user-definable program areas
Networked points in 127 from Tier 1 controllers
512 from Tier 2 controllers
Networked points out 64 to Tier 1 controllers
64 to Tier 2 controllers
PID control loops 8 PID control loops
Program variables 256 — Software selectable as analog or digital
with standard and custom units of measure
Time keeping Real-time clock with power backup for 72
hours.
Programmable for automatic daylight saving
time by date, day of month and time of day.
Tables 5 user defined
Schedules
Weekly schedules 8 each with 2 override days
Annual schedules 4

KMD-5205 and KMD-5270 Installation and Operation
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About the controllers
Specifications
7
Logging
Trend logs 16 trend logs each supporting up to 6 analog,
digital or virtual elements or points. Trend logs
displayed as text or graphics.
Runtime logs 16 runtime logs with time and date stamp and
cumulative runtime
Custom graphics 32 system groups each of which can manage 64
points with animated and color graphics.
Requires WinControl XL Plus to view and edit
graphics.
KMD-5270 models serves the background
system group graphic to browser accessible web
pages.
Security Six operator access levels
256 names with passwords
Alarms Alarm buffering up to 16 alarms
On-board 68-character alarm or maintenance
text messages
Memory
Flash memory 2 megabyte non-volatile flash memory
Ram 2 megabyte with six-hour backup
Programs and program parameters are stored in
non-volatile memory.
Communication ports
Ethernet One Ethernet 10Base-T port for KMD Tier 1 and
optional BACnet 8802.3
RS-485 Connects to either KMC Tier 2 or Modus RTU
controllers.
Connector type is removable screw terminal
block. Wire size 14–22 AWG
Serial Serial 9-pin connector for directly connecting to
a computer serial port or optional external
modem for remote operation.

KMC Controls
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About the controllers
Specifications
8
Supported network protocols
KMDigital All WebLite controllers support connections to
controllers on KMDigital networks.
Tier 1—10Base-T Ethernet port supports
connection to 31 KMC Tier 1 controllers.
Tier 2—Supports connections to 64 KMDigital
controllers on the RS–485 port. KMD Tier 2 is
not available on models with Modbus RTU
protocol.
BACnet Connects to the BACnet internetwork as a
BACnet Ethernet 8802.3 device.
Modbus Supports connection to Modbus slave
controllers over the RS-485 port.
RS-485, half-duplex (2-wire)
9600, 19,200 or 38,400 baud.
Power loss Automatic restart on power failure
Compatibility
Software For full feature capability use WinControl XL
Plus 2.1 or later.
Controllers Compatible with Tier 1 controllers firmware
build 2.0 or a later release.
Regulatory UL 916 Energy Management Equipment
FCC Class A, Part 15, Subpart B
CE mark
Internet (KMD-5270 models only)
Browser access Use a standard internet browser to view and
change the following: Inputs. Outputs,
Variables, Controllers, System Groups, Trend
Logs, Run Time Logs, Weekly and Annual
Schedules, Alarm Summary.
E-mail Requires access to SMTP e-mail server with
static IP address. Sends text messages, logs and
data points.
Supply voltage 24 volts AC, –15%, +20% 25 VA
Environmental limits
Operating 32 to 120°F (0 to 49°C)
Shipping –40 to 140°F (–40 to 60°C)
Humidity 0–95% non-condensing relative humidity
Weight 16 ounces (454 grams)

KMD-5205 and KMD-5270 Installation and Operation
Revision J
About the controllers
Specifications
9
Dimensions
Table 1-1 Mounting dimensions
A B C D Height (not
shown)
6.56 in. 9.00 in. 6.00 in. 6.00 in. 0.98 in.
167 mm 229 mm 152 mm 152 mm 25
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
1
2
3
4
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
5
6
7
8
PWR
S-LAN
PC
COLL
Rx
Tx
A
B
C
D

KMC Controls
Revision J
About the controllers
Models and options
10
Models and options See Table 1-2 on page 10 for available models and protocols.
Accessories and
replacement parts
The following accessories and replacement parts are available from KMC
Controls, Inc.
Output override boards
HPO-6701 Triac output
HPO-6702 Short protected analog output
HPO-6703 Relay, normally open contacts
HPO-6704 4–20mA current loop
HPO-6705 Relay, normally closed contacts
HPO-6802 Cover for output boards
Power transformer
XEE-6111-40 Single-hub 120 volt transformer
XEE-6112-40 Dual-hub 120 volt transformer
Connecting cables
KMD-5673 Six-foot computer-to-controller cable
KMD-5674 six-foot modem-to-controller cable
Replacement parts
902-600-05 Fast-acting, 1.6 Ampere 5 x 20 mm fuse
HPO-0054 FUSE BULB 863-617-03 (10/Pkg Min Qty)
HPO-0063 2-PIN KMD JUMPER (5/Pkg Min Qty)
Table 1-2 Available models
Model Protocol
KMD Tier 1 KMD Tier 2 Browser enabled BACnet 8802.3 Modbus RTU
KMD-5205 ◆◆
KMD-5205-005 ◆ ◆
KMD-5205-006 ◆◆◆
KMD-5270 ◆◆◆
KMD-5270-001 ◆◆◆ ◆
KMD-5270-005 ◆◆ ◆
KMD-5270-006 ◆◆◆◆

KMD-5205 and KMD-5270 Installation and Operation
Revision J
About the controllers
Controls and connections
11
Controls and
connections
Before installing a KMD-5205 or KMD-5270, take some time to become familiar
with the location of the components of the controller.
Illustration 1-1 Control and connection terminal locations
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
1
2
3
4
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
5
6
7
8
PWR
S-LAN
PC
COLL
Rx
Tx
Pull-up jumpers
Input terminals
Input ground
terminals
RS-485 end-of-line
termination switches
Isolation bulbs
RS-485
RS-232
Ethernet
Output bank 1
Output bank 2
Input power
Power supply fuse
Power jumper
Indicator LEDs

KMC Controls
Revision J
About the controllers
Safety considerations
12
Safety considerations KMC Controls 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 or equipment or property damage
if instructions are not followed.
Note
Notes provide additional information that is important.
Detail
Provides programing tips and shortcuts that may save time.
Danger

KMD-5205 and KMD-5270 Installation and Operation
Revision J 13
SECTION 2
Installing the controllers
This section provides important guidelines for installing KMC direct
digital controllers. Review this information carefully for proper
installation.
Mounting Mount the controller inside of a metal enclosure. KMC Controls recommends
using a UL-approved Enclosed Energy Management Equipment Panel such as a
KMC model HCO-1034, HCO-1035 or HCO-1036. Insert #6 hardware through the
two mounting holes on each side of the controller to securely fasten it to a flat
surface. See Dimensions on page 9 for mounting hole locations and dimensions. To
maintain RF emission specifications, use either shielded connecting cables or
enclose all cables in conduit.
Connecting inputs The controllers include eight universal inputs. Each input can be configured with
software to receive either analog or digital signals. By using the optional pull-up
resistors, either passive or active devices may be connected to the inputs. For
additional information, see the application note AN0504L, Connecting inputs and
outputs to KMC controllers.
Pull-up resistors
For passive input signals, such as thermistors or switch contacts, use a pull-up
resistor. For KMC thermistors and most other applications place the moveable
jumper in the 10K position.
4–20 mA inputs
To use a 4–20 current loop input, connect a 250 ohm resistor from an input to
ground. The resistor will convert the current input to a voltage which can be read
by the controller analog-to-digital converter. Place the moveable pull-up jumper
in the NONE position.
Pulse inputs
Connect pulse inputs under the following conditions:
◆If the pulse input is a passive input such as switch contacts, then place the
input pull-up jumper to the 10K position.
◆If the pulse is an active voltage (up to a maximum of +5 volts DC), then place
the input pull-up jumper in the NONE position.

KMC Controls
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Installing the controllers
Connecting outputs
14
Ground terminals
Three input ground terminals are located next to the input terminals. Up to two
wires, size 12–22 AWG, can be clamped into each ground terminal. If more than
two wires must be joined at a common point, use an external terminal strip to
accommodate the additional wires.
Connecting outputs All eight outputs are universal and can be configured by software to operate
either analog or digital devices. Connect the device under control between the
output terminal and one of the ground (G) terminals on the same bank.
Override cards
For large relays or devices that cannot be powered directly from a standard
output, install an output override card. Override cards provide:
◆A wide choice of output signals.
◆A slide switch for automatic or manual control.
◆An LED for assessment of the output state.
Install the output override cards in the area under the plastic cover next to the
output terminals. The following output cards are available from KMC Controls.
Grounds and Switched Commons
When using an output override card, use the SC terminal instead of the ground
(G) terminal as signal common. Use the SC terminal in the same output bank as
the output terminal.
Table 2-1 Output override cards
Card model number Output type
HPO-6701 Triac
HPO-6702 0–10 volts DC analog
HPO-6703 Normally open contact
HPO-6704 4–20 milliampere current loop
HPO-6705 Normally closed contact

KMD-5205 and KMD-5270 Installation and Operation
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Installing the controllers
Connecting to networks
15
Connecting to
networks
Each controller in a KMC digital network may be used as either a stand-alone
controller or connected to other controllers in a network. The KMD-5205 and
KMD-5270 controllers can be connected to other KMC controllers through two
different types of networks.
◆Connections to KMD Tier 1 controllers and BACnet 8802–3 devices use
standard Ethernet wiring and hardware.
◆KMD Tier 2 controllers and Modbus controllers use EIA–485 wiring and
hardware.
KMC Tier 1 networks LAN connections
Connect a standard Ethernet cable between the Ethernet connector on the
controller and a port on a network hub or router. You may connect up to 31 Tier 1
controllers in a system using Ethernet. In addition to allowing the maximum LAN
controllers, multiple computers can access the system through the network. See
Initializing with HCM on page 27 for Ethernet configuration.
KMC Tier 2 networks Connect KMC Tier 2 controllers to a KMD-5205 or KMD-5270 at the RS-485
connector. The KMC Tier 2 network uses shielded twisted pair cable to connect
controllers together. See Initializing with HCM on page 27 for configuring a
controller for Tier 2 network operation.
Note
KMD Tier 2 controllers cannot be connected to KMD-5205 or KMD-5270 when
the Modus option is enabled.

KMC Controls
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Installing the controllers
KMC Tier 2 networks
16
Tier 2 wiring
You may connect up to 64 KMDigital controllers to the RS–485 connector. Use
approved shielded cable and the following principles when connecting a
controller to a Tier 2 (sub LAN) network:
◆Use 18 gauge, twisted pair, shielded cable with capacitance of no more than
50 picofarads per foot for all network wiring. Belden cable model #82760
meets the cable requirements.
◆Connect the Aterminal in parallel with all other A or -A terminals.
◆Connect the B terminal in parallel with all other B or +B terminals.
◆Connect the shields of the cable together at each controller.
◆Connect the shield to an earth ground at the other end.
◆Use a KMD–5575 repeater if the cable length will exceed 4000 feet
(1220 meters). Use no more than seven repeaters per Tier 2 network.
◆Place a KMD–5567 surge surpressor in the cable where it exits a building.
Tier 2 end of line termination switches
The controllers on the physical ends of the RS-485 wiring segment must have
end-of-line termination installed for proper network operation. Set the end-of-line
termination to On using the EOL switches. The KMD-5205 and KMD-5270
end-of-line termination is set with two switches located near the RS–485
connector. Termination in other KMC controllers may be set with moveable
jumpers or fixed resistors.
Illustration 2-1 Connecting controllers to a Tier 2 network
A
B
G
B
G

A
G
B
A
G
B
A
B
A G
B
A G
Earth ground Ground shield in one place only.

KMD-5205 and KMD-5270 Installation and Operation
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Installing the controllers
BACnet 8802-3 (optional)
17
Note
Set the End-of-Line termination at the controllers where only one wire is
attached to the A and B terminals.
BACnet 8802-3
(optional)
Connect models with the BACnet option to the BACnet internetwork through the
same Ethernet 10Base-T connection as the Tier 1 connection. For access to devices
on a BACnet internetwork you must do the following:
◆The BACnet internetwork must include at lease one 8802-3 network.
◆The controller must be connected to the same Ethernet broadcast domain
segment as one of the BACnet 8802-3 networks.
◆If the internetwork does not include an 8802-3 network, install a router to
route traffic from the existing BACnet network protocols to Ethernet 8802-3.
For internetworks that include MS/TP or BAcnet IP, use a BAC-5050. For
addition details on BACnet networks, see application note AN0404A,
Planning BACnet Internetworks, which is available on the KMC web site.
Illustration 2-2 Termination switches
Illustration 2-3 End-of line termination
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
1
2
3
4
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
5
6
7
8
PWR
S-LAN
PC
COLL
Rx
Tx
WD
Termination On
Termination switch
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
1
2
3
4
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
5
6
7
8
PWR
S-LAN
PC
COLL
Rx
Tx
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
1
2
3
4
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
5
6
7
8
PWR
S-LAN
PC
COLL
Rx
Tx
Set end-of-line termination to
On in these controllers only

KMC Controls
Revision J
Installing the controllers
Modbus (optional)
18
Modbus (optional) Connect Modus slave controllers to a KMD-5205 or KMD-5270 at the RS-485
connector. The Modbus network uses shielded twisted pair cable to connect
controllers together. To set up the controller, see Initializing with HCM on page 27
and Setting up for Modbus networks on page 32 for configuration details.
Modbus wiring
Connect Modbus slave devices to the RS-485 connector. Use approved shielded
cable and the following principles when connecting a controller to a Modbus
network:
◆Use 18 gauge, twisted pair, shielded cable with capacitance of no more than
50 picofarads per foot for all network wiring. Belden cable model #82760
meets the cable requirements.
◆Connect the Aterminal of the KMD controller in parallel with the minus (-)
terminals on the Modbus devices.
◆Connect the Bterminal of the KMD controller in parallel with the plus (+)
terminals on the Modbus devices.
◆Connect the shields of the cable together at each controller.
◆Connect the shield to an earth ground at one end only.
◆Place a KMD-5567 surge surpressor in the cable where it exits a building.
Note
In addition to these Modus wiring requirements, verify equipment specific
Modbus wiring requirements in the manuals supplied with the Modus devices.
Illustration 2-4 Connecting the Modbus network
A
B
G
+
-
+
-
B
G
+

+
A
Ground shield in
one place only.
KMD-5205 or
KMD-5270
with Modbus
Modbus
devices

KMD-5205 and KMD-5270 Installation and Operation
Revision J
Installing the controllers
Modbus (optional)
19
Modbus end-of-line termination switches
The controllers on the physical ends of the Modus wiring segment must have
end-of-line termination installed for proper network operation. For the KMD
controllers the end-of-line termination is set with two switches located near the
RS-485 connector. Set the end-of-line termination to On using the EOL switches.
End-of-line termination for the connected Modbus devices may be set with
moveable jumpers or fixed resistors. Verify termination methods for the Modbus
devices in the manuals supplied with the Modbus devices.
Note
Set the end-of-line termination at the controllers where only one wire pair is
attached to the Aand Bterminals.
Illustration 2-5 End-of-line termination
Set end-of-line
termination to On
in these controllers
only

KMC Controls
Revision J
Installing the controllers
Connecting power
20
Connecting power The controllers require an external, 24 volt, AC power source. Use the following
guidelines when choosing and wiring transformers.
◆Use a KMC Controls Class–2 transformer of the appropriate size to supply
power to the controllers.
◆When installing a controller in a system with other controllers, you may
power multiple controllers with a single transformer as long as the total
power drawn from the transformer does not exceed its rating and phasing is
correct.
◆If several controllers are mounted in the same cabinet, you can share a
transformer between them provided the transformer does not exceed 100 VA
or any regulatory requirements.
◆Do not run 24 volt, AC power from within an enclosure to external
controllers.