KMC Controls KMD-5210 Operating instructions

Revision E
Installation and Operation Guide
KMD-5210 LAN Controller
KMD-5210–001 LAN Controller with BACnet 802.3
KMD-5210–002 LAN Controller with BACnet MS/TP
883-019-07E

KMC Controls
Revision E2
Important notices ©2012, KMC Controls, Inc.
WinControl and WinControl XL is a registered trademark of KMC Controls, Inc.
TotalControl is a trademark 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]

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KMD–5210 Installation and Operation
Revision E 3
Contents
Section 1
About the LAN controller
Introduction .......................................................................................................................... 5
BACnet options .................................................................................................................... 5
Specifications ........................................................................................................................ 6
Options and Accessories ..................................................................................................... 9
Controls and Connections ................................................................................................ 10
Safety Considerations ....................................................................................................... 11
Section 2
Installation
Mounting ............................................................................................................................ 13
Network connections ........................................................................................................ 14
EIA–485 networks .............................................................................................................. 16
BACnet networks ............................................................................................................... 18
Planning for input and output modules ........................................................................ 20
Module installation ........................................................................................................... 21
Connecting Power ............................................................................................................. 22
Connecting to a Computer ............................................................................................... 23
Section 3
Operation
Applying power .................................................................................................................27
Lights and indicators ......................................................................................................... 27
Resetting the controller ..................................................................................................... 29
Section 4
Configuration and programming
Related materials ............................................................................................................... 31
Programming Considerations .......................................................................................... 31
Configuring a controller with HCM ............................................................................... 32
Programming for BACnet in WinControl XL ................................................................ 36
Access to the LAN Controller from BACnet ................................................................. 37
Firewalls and network communications ........................................................................ 37
System time keeping ......................................................................................................... 37

KMC Controls
Revision E4


KMD–5210 Installation and Operation
Revision E 5
SECTION 1
About the LAN controller
This section provides a general introduction to the KMD-5210 LAN
Controller. It also introduces safety information. Review this
material in its entirety before installing or operating the controller.
Introduction The KMD-5210 LAN Controller is a programmable, direct digital controller
used to facilitate high-level, peer-to-peer network communications for
facilities management purposes. The LAN Controller may be operated in a
stand alone configuration or as part of a fully networked digital system to
intelligently monitor and control HVACR equipment.
The KMD-5210 uses a token passing protocol in Tier 1 networks using an
Ethernet network to communicate with other LAN Controllers. The LAN
Controller also supports Tier 2 networks with two dedicated EIA–485 ports.
Up to 32 KMD-5210 controllers can be integrated into a single peer-to-peer
network, each supporting up to 124 nodes on a Tier 2 network.
The controller also supports remote access through a modem port and
provides two ports for direct connection with up to two PCs. The firmware in
the controller uses a high-level, easy-to-learn programming language to
ensure reliability, rapid programming, and compatibility with future KMC
system. This programming function is available from within the KMC
Controls WinControl application.
BACnet options BACnet 802.3 The KMD-5210-001 adds BACnet functionality to the LAN
Controller. Through Control Basic statements the controller communicates
with 802.3 BACnet devices on the same Ethernet broadcast segment.
BACnet MS/TP The KMD-5210-002 adds BACnet MS/TP functionality to the
LAN Controller functionality. By using Control Basic programming, the
controller exchanges data with native BACnet devices on an MS/TP network.

KMC Controls
Revision E
About the LAN controller
Specifications
6
Specifications
Processor Motorola 68360, 32–bit, 33 MHz
Memory
Flash 2 megabytes, nonvolatile, operating programs
and data storage
RAM 2 megabytes, 72–hour capacitor backup
Inputs and Outputs The KMD-5210 controller includes eight
universal I/O ports for optional input and
output modules. Connect up to eight KMD-5220
input modules, eight KMD-5221 output
modules or a combination of input and output
modules in any combination.
I/O Ports Eight, 16–pin connectors. Software selectable as
analog or digital standard or custom units of
measure.
Inputs 16–bit analog-to-digital (A/D)
Software selectable as analog or digital standard
or custom units of measure. Install up to 8, 16
input modules for up to 128 universal inputs.
Output 12–bit digital to analog (D/A)
Communications
Tier 1 EIA–485 protocol at rates up to 38 kilobaud.
Connector type is a three-screw terminal block,
12–22 AWG wire.
Note: Use the Tier 1 connection only when
replacing KMD–5110 MultiNet controllers and
Ethernet is not available. Contact KMC Controls
techncial support for networking details.
Tier 2 A and B EIA–485 protocol at rates up to 38 kilobaud.
Connectors are three-screw terminal blocks,
12–22 AWG wire. Two ports, each of which
support up to 124 KMC Tier 2 controllers.
EIA–485 EIA–485 protocol at rates up to 38 kilobaud.
Connector is a three-screw terminal block,
12–22 AWG wire. Supports BACnet MS/TP in
KMD-5210–002.
Modem EIA–232 in parallel with Computer B. Dial-in
and dial-out for with alarm and paging
capability, 9–Pin (DB-9).
Computer A and B Two EIA–232 ports, operate up to 38.4 kilobaud.
Connectors are three-screw terminal blocks,
12–22 AWG wire.
Ethernet 10baseT, RJ–45 supports up to 31 networked
Tier 1 controllers and BACnet 802.3 in KMD-
5210–001

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KMD–5210 Installation and Operation
Revision E
About the LAN controller
Specifications
7
Programmable Features
Control Basic Programs 128 user-definable program areas
Networked Points In 512 from each Tier 2 network
127 from Tier 1 network
Networked Points Out 64 to each Tier 2 network
64 out to a Tier 1 network
PID Control Loops 64 PID control loops
Program Variables 256 - Software selectable as analog or digital
with standard or custom ranges, manually set or
program driven values
Time keeping Real-time clock with power backup.
Programmable for automatic daylight saving
time by date, day of month and time of day.
Tables 5 user defined
Logging
Trend Logs 96 trend logs each supporting up to 6 analog,
digital, or virtual elements or points
Runtime Logs 28 runtime logs with time/date stamp and
cumulative runtime
Schedules
Weekly Schedule 32 schedules with 2 override days
Annual Schedule 16 for holiday schedules
Alarms Alarm buffering for up to 128 alarms
50 alarm messages for distribution
On-board 68-character alarm or maintenance
text messages
Power Loss Power fail with auto restart
On-board real-time clock with 72–hour
capacitor backup.
Security Six operator access levels
256 operator names with passwords
Custom Graphics 64 system groups each of which can manage 160
points with animated and color graphics.
Regulatory UL 916 Energy Management Equipment listed
CE compliant
FCC Class B, Part 15, Subpart B
SASO PCP Registration KSA R-103263

KMC Controls
Revision E
About the LAN controller
Specifications
8
Power Supply Requires KMD–5563, International-ready 120/
240 VAC, 1.35 ampere power supply
Environmental Limits
Operating 32° to 120° F (0° to 49° C)
Shipping –40° to 140° F (–40° to 60° C)
Humidity 0–95% RH, non-condensing
Weight 1.8 pounds (816 grams)
Compatibility
Software WinControl XL Plus 1.06 or later
TotalControl 1.8.1 or later
Controllers Compatible with Tier 1 controllers firmware
build 2.01 or later
Dimensions
Illustration 1-1 KMD-5210 Components
Table 1-1 KMD-5210 Dimensions
ABCDEF
Height
(not shown)
10.50 in. 6.50 in. 0.25 in. 10.00 4.00 in. 1.25 in. 0.98 in.
267 mm 165 mm 6 mm 254 mm 102 mm 32 mm 25 mm
C
A
B
D
E
F

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KMD–5210 Installation and Operation
Revision E
About the LAN controller
Options and Accessories
9
Options and
Accessories Modules
KMD-5220 Input Module
KMD-5221 Output Module
Ribbon Cables for Input and Output Modules
KMD-5660 6 inch (15 cm) ribbon cable
KMD-5668 9 inch (23 cm) ribbon cable
KMD-5661 14 inch (36 cm) ribbon cable
KMD-5662 19 inch (48 cm) ribbon cable
KMD-5663 24 inch (61 cm) ribbon cable
Power
KMD-5563 International-ready power supply, 120/240
volts AC, 1.35 amperes
XEE-6112-100 100 VA Transformer, 24 volts AC (required only
for KMD-5221 output module)
Upgrades
HTO-1102 Flash Kit Module; KMD/BAC-5XXX,
BAC-7XXX (Replaces KMD-5696)
Enclosures
HCO-1035 Panel Enclosure (20 x 24 x 6 inches)
(508 x 610 x 152 mm)
HCO-1036 Panel Enclosure (24 x 36 x 6 inches)
(610 x 914 x 152 mm)

KMC Controls
Revision E
About the LAN controller
Controls and Connections
10
Controls and
Connections Before installing the KMD-5210 LAN Controller, take some time to become
familiar with the controller layout and components.
Illustration 1-2 Controls and indicators
Reset button
(Beneath cover) Power Tier 1
EIA–485 Tier 2 EIA–485 Modem
BACnet
MS/TP
EIA–232
for PC
Ethernet
and
BACnet
802.3
LED
Status
Display


KMD–5210 Installation and Operation
Revision E
About the LAN controller
Safety Considerations
11
Safety
Considerations KMC controls assumes the responsibility for providing you with a safe
product and safety guidelines for its proper 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 no t followed.
Warning
Warning represents hazards which 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 important information.
Detail
Provides programming tips and shortcuts which may save time.

KMC Controls
Revision E
About the LAN controller
Safety Considerations
12

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KMD–5210 Installation and Operation
Revision E 13
SECTION 2
Installation
This section provides important instructions and guidelines for
installing the KMD-5210 LAN Controller. Carefully review this
information prior to 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 or #8 hardware
through the two mounting holes on each side of the controller to securely
fasten it to a flat surface. See Illustration 1-2 on page 10 for mounting hole
locations and dimensions. To maintain RF emission specifications, use either
shielded connecting cables or enclose all cables in conduit.
Note
Provide sufficient clearance around the controller for cables and wiring.
◆Allow a minimum of 3 inches (7.6 cm) of clearance at the top edge of the
controller for the power and modem connectors.
◆Allow a minimum of 1.5 inches (3.8 cm) of clearance for the ribbon cables
at the bottom of the controller.
Illustration 2-1 Mounting details
Allow 1.5 in. (3.8 cm) for cables
Allow 3.0 in. (7.6 cm) for cables
Mounting
holes Mounting
holes

KMC Controls
Revision E
Installation
Network connections
14
Network
connections Prior to making network connections, determine which connections will be
used and how the network will be configured. An example of a typical
installation is shown in Illustration 2-2.
Each KMD-5210 in a KMC digital network may operate in either a stand-alone
mode or connected by network to other controllers. The LAN Controller may
be connect to other controllers using one or more of four network
technologies.
◆KMC Tier 1 networks using standard 10BaseT, CAT 5 Ethernet cabling or
EIA–485 wiring and hardware.
◆KMC Tier 2 networks using EIA–485 wiring and hardware.
◆BACnet 802.3 networks using standard 10BaseT CAT 5 Ethernet cabling
(KMD-5210-001 only)
◆BACnet MS/TP using EIA–485 wiring and hardware (KMD-5210-002
only)
Illustration 2-2 Typical network configuration
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STATUS
KMD-5210
CONNECTOR
OUTPUTS
SC
1-4
SC
5-8
SC
9-12
SC
13-16
SWITCHED
COMMONS
24 AC
STATUS H O A
STATUS H O A
O-R
O-R
O-R STATUS H O A
O-R STATUS H O A
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
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5
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8
STATUS H O A
STATUS H O A
O-R
O-R
O-R STATU S H O A
O-R STATU S H O A
O-R STATU S H O A
O-R STATUS H O A
O-R STATU S H O A
O-R STATU S H O A
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STATUS
KMD-5210
CONNECTOR
INPUT JUMPERS
4-20 MA
1K PULL-UP
10K PULL-UP
NO PULL-UP
TRANSDUCER
POWER
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
15 DC
INPUT +
INPUTS
~
+
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STATUS
KMD-5210
CONNECTOR
OUTPUTS
SC
1-4
SC
5-8
SC
9-12
SC
13-16
SWITCHED
COMMONS
24 AC
STATUS H O A
STATUS H O A
O-R
O-R
O-R STATUS H O A
O-R STATUS H O A
O-R STATUS H O A
O-R STATU S H O A
O-R STATUS H O A
O-R STATUS H O A
1
2
3
4
5
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7
8
STATUS H O A
STATUS H O A
O-R
O-R
O-R STATU S H O A
O-R STATU S H O A
O-R STATU S H O A
O-R STATUS H O A
O-R STATU S H O A
O-R STATU S H O A
1
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STATUS
KMD-5210
CONNECTOR
INPUT JUMPERS
4-20 MA
1K PULL-UP
10K PULL-UP
NO PULL-UP
TRANSDUCER
POWER
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
15 DC
INPUT +
INPUTS
Modem
Power
Supply
RS-485
Tier 1
A
TERMINAL
CONTROLLER
U. .
Terminal
Controller
Local
Controller
HEAT PUMP
TERMINAL
CONTROLLER
av
Terminal
Controller
Local
Controller
Tier 1 KMC Ethernet
(BACnet 802.3
Optional)
RS-485
(Optional BACnet
MS/TP)
INPUT MODULE
KMD-5220 INPUT MODULE KMD-5220 OUTPUT MODULE KMD-5221 OUTPUT MODULE KMD-5221

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KMD–5210 Installation and Operation
Revision E
Installation
Network connections
15
Up to 32 LAN Controllers can be connected to the same Ethernet backbone in
a common Ethernet network. This configuration also allows multiple PCs to
access the system through the Ethernet network.
Connect the controller to the network by connecting a standard 10BaseT
Ethernet cable (CAT 5) to the Ethernet/BACnet port on the controller and to a
port on the network hub or router. (See “Ethernet Settings” later in this guide
for recommended Ethernet Software Settings.)
Note
For reliable operation, use CAT 5 or equivalent Ethernet cables for all
connections. If cables are custom made, they must meet the CAT 5
specification.
Illustration 2-3 Typical Ethernet network configuration
Ethernet hub
or router

KMC Controls
Revision E
Installation
EIA–485 networks
16
EIA–485 networks The KMD-5210 LAN Controller provides four active EIA–485 connection
ports.
◆Tier 1
◆Tier 2A
◆Tier 2 B
◆EIA–485 for BACnet MS/TP
Use the Tier 1 port (marked Main Net on older controllers) to connect several
KMD-5210. This is an alternative to connecting LAN Controllers to each other
with Ethernet. This port will allow up to 31 controllers to be connected
together by network.
Note
The Tier 1 EIA–485 port is disabled when the controller is assigned an IP
address for operation on an Ethernet network. Tier 2 A and Tier 2 B will
function normally. Ethernet IP addresses are configured with Hardware
Configuration manager.
The Tier 2 A and Tier 2 B ports are for connection to Tier 2 networks. Each port
supports up to 124 individual controllers.
Note
For reliable operation, use Belden cable model #82760 or equivalent (18 gauge,
twisted, shielded, 50 picofarads or less) for all EIA–485 network wiring.
Wiring notes
All EIA–485 network segments (KMC protocol or BACnet) use the same
wiring principles.
◆Use approved shielded cable and the following principles when
connecting a controller to a Tier 2 (sub LAN) network:
◆Connect no more than 31 KMC addressable controllers or devices to the
Tier 1 RS-485 connector.
◆Connect no more than 124 KMC programmable controllers to the
Tier 2 A or Tier 2 B connectors.
◆Connect the Aterminal in parallel with all other Aterminals.
◆Connect the Bterminal in parallel with all other Bterminals.
◆Connect the shields of the cable together at each controller.
◆Connect the shields to an earth ground (if available) or chassis ground
only at one end of the segment; tape back the shield ground at the other
end.
◆Use a KMD–5575 repeater between every 32 Tier 2 controllers or if the
cable length of a Tier 1 or Tier 2 network exceeds 4000 feet (1220 meters).
Use no more than seven repeaters per network.
◆Place a KMD–5567 surge suppressor in the cable where it exits a
building.

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KMD–5210 Installation and Operation
Revision E
Installation
EIA–485 networks
17
Refer to Illustration 2-4 for an example of typical EIA–485 connections.
End-of-line termination
Each EIA–485 network segment requires end-of-line termination for proper
operation of the network. Proper termination prevents signal degradation and
EMI type interference with other system wiring. Termination jumpers are
located on both sides of each EIA–485 connector (one each for the A and B
terminals; see Illustration 2-5.)
To activate the end-of-line termination, leave the jumpers in place. If
termination is not required, position the jumpers so they only cover one pin
on the header.
Illustration 2-4 Typical EIA–484 Wiring Configuration
Illustration 2-5 End-of-line Termination Jumpers
G
A
B
G
G
B
A
G
B
A
A
B
KMC controller
connections
Input termination jumpers
(Two at each EIA–485 connector)
Jumpers set for end-of-line
termination removed.

KMC Controls
Revision E
Installation
BACnet networks
18
Note
The controller with only one EIA–485 cable connected is normally the
end-of-line. This is also the controller where the cable shield ground is tied to
earth or a chassis ground
.
BACnet networks The KMD-5210 LAN Controller supports an optional Class 3 Conformance
Level of the BACnet specification. The BACnet protocol is implemented using
either one or the other of the following network configurations.
◆Ethernet 802.3 specification in KMD-5210-001
◆MS/TP EIA–485 in KMD-5210—002.
See the section Programming for BACnet in WinControl XL on page 36 for details on
BACnet features.
Note
The BACnet options are licensed for each controller. To upgrade a KMD-5210
controller to BACnet, contact KMC Controls for license information.
BACnet 802.3
The KMD-5210–001, the BACnet 802.3 version of the LAN controller, connects
to the LAN in the same manner as the standard LAN controller. See Network
connections on page 14.
The BACnet internetwork most likely will use one or more BACnet routers to
manage the BACnet internetwork and devices. The KMD-5210–001 must be
connected to the same Ethernet broadcast domain segment as at least one
BACnet router and the router must be enabled for BACnet 802.3 traffic. To
configure a KMD-5210–002 for network connections, see BACnet configuration
on page 35.
Illustration 2-6 End-of-line termination jumper sample for a Tier 1 network
Install jumpersRemove jumpers
Install jumpers

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KMD–5210 Installation and Operation
Revision E
Installation
BACnet networks
19
BACnet MS/TP
Connect a KMD-5210–002 controller to a BACnet MS/TP network at the
connector EIA–485. See EIA–485 networks on page 16 for network wiring
techniques. To configure a KMD-5210–002 for network connections, see
BACnet configuration on page 35.
Illustration 2-7 BACnet MS/TP connections
Shield +–

KMC Controls
Revision E
Installation
Planning for input and output modules
20
Planning for input
and output
modules To connect inputs or output devices to a KMD-5210 controller, use KMD-5220
input and KMD-5221 output modules. The KMD-5210 controller includes
eight universal I/O ports for up to eight KMD-5220 input modules, eight
KMD-5221 output modules or any combination of up to eight modules.
Each module connects to the controller using a flat ribbon cable. When
connecting input and output modules, use the following guidelines.
◆Connect the first KMD-5220 input module to connector I/O Card 1; add
continue adding input modules from left to right
◆Connect the first KMD-5221 output module to connector I/O Card 8 and
continue adding output modules from right to left.
◆Use ribbon cables no longer than 24 inches (61 cm).
◆KMD-5221 output modules require an output transformers.
Illustration 2-8 Typical input and output module connection