KMC Controls KMD-5831 Original operating instructions

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Installation & Operation Guide
KMD-5831
Programmable Loop Controller PLC-28 Direct Digital Controller
902-019-04B
(Shown with optional Override Board Cover)

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Introduction
This section provides a brief overview of the KMD-5831 Programmable Loop
Controller PLC-28 and the KMD-5821 Programmable Loop Controller PLC-16 +
Direct Digital Controllers. Review this material before you attempt to install the
controller.
For clarity we will focus on the KMD-5831 but all installation and operating
instructions apply equally to the KMD-5821.
Illustration 1 shows the major controller components and their locations. The
KMD-5821has fewer inputs and outputs.
Note:
Additional components are located under the blank cover. We will cover these in
detail later in this document.
Illustration 1. Controller Components
O - R ST A T U S H O A
O - R ST A T U S H O A
O - R ST A T U S H O A
O - R ST A T U S H O A
1
2
3
4
O - R ST A T U S H O A
O - R ST A T U S H O A
O - R ST A T U S H O A
O - R ST A T U S H O A
5
6
7
8
Input Terminal
Blocks
Input Pull-Up
Switches
RS–485
Connector
Isolation
Lamps
RJ–12
Connector
Output Terminal
Blocks
Grounds
Status LEDs
Blank
Cover
Override
Board
Cover
AC Power
Input

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Installation
This section provides important instructions and guidelines for installing the
KMD-5831 Programmable Loop Controller PLC-28 Direct Digital Controller.
Carefully review this information prior to attempting installation.
Mounting
Use the four mounting holes to securely mount the controller using #6 hardware
inside a UL-approved Enclosed Energy Management Equipment Panel or other
suitable protective enclosure. Refer to Illustration 2.
Input Connections
Universal Inputs
Wiring connections are made depending on the intended application. Sixteen
Universal Inputs are provided on the controller. Observe the following guide-
lines. (Refer to Illustration 2.)
◆Connect device inputs to the input terminal connections (+).
◆Connect input grounds to the associated ground terminal (-).
Illustration 2. Connector Detail
O - R ST A T U S H O A
O - R ST A T U S H O A
O - R ST A T U S H O A
O - R ST A T U S H O A
1
2
3
4
O - R ST A T U S H O A
O - R ST A T U S H O A
O - R ST A T U S H O A
O - R ST A T U S H O A
5
6
7
8
6.00"
6.00"

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◆If input pull-ups are required, refer to “Configuration” later in this section.
◆Wiring terminals are suitable for up to two 12–22 AWG wires. If more than
two wires are required, use an external terminal strip for additional connec-
tions.
Note:
Pulse inputs may be used under the following conditions:
◆If the pulse input does not use a voltage variation, then leave the input pull-up
in the “On” position.
◆If the pulse produces voltage peaks (up to +5 VDC max.), then the input pull-
up must be set to the “Off” position.
◆The maximum pulse rate is 8 HZ (8 pulse/sec).
Connecting Outputs
Twelve Universal Outputs are available for output connections labeled as 1–12 on
the output terminal blocks. The outputs are grouped into three groups of four
outputs each with a shared grounds (labeled “SC”) in each block.. Each output
can produce 50 mA at +12 VDC. If a greater current is required, KMC recom-
mends the use of Override Boards discussed later in this section.
A separate ground block provides six additional ground connections.
Network Connections
The controller provides connections for two types of RS–485 circuits.
RJ-12
The RJ–12 connector provides a six-wire RS-485 connection to a modem or PC
using the KMD-5559 CommTalk Data Exchange Module. Simply connect a
suitable RJ-12 cable between the devices.
RS-485 Inputs
A RS–485 terminal is available for connections to a network of controllers If the
Controller is at the End-of-Line, refer to “Configuration” after connections are
completed.
Detail
The End-of-Line connection will have only one wire attached to the A and B
terminals.
◆For reliable operation, use Belden cable model #82760 or equivalent (18 gauge,
twisted, shielded, 50 picofarads or less) for all network terminal block connec-
tions.
◆Connect the nodes of the network in a daisy-chain arrangement. This means:
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.
Installation KMD-5831 PLC-28 Direct Digital Controller Installation & Operation Guide

5
◆Connect the shields to an earth ground (DO NOT use a chassis ground) only at
one end of the segment; tape back the shield ground at the other end.
Wiring Notes
Use approved shielded cable and the following principles when connecting a
controller to a network:
◆Connect no more than 124 Tier 2 KMC addressable controllers or devices to
the RS-485 network.
◆Connect the nodes of the network in a daisy-chain arrangement. This means:
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 at only 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 the 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.
Refer to Illustration 3 for an example of typical RS-485 connections.
KMD-5831 PLC-28 Direct Digital Controller Installation & Operation Guide Installation
Illustration 3. Typical RS-485 Wiring Configuration
KMC Controlle
r
Connections
Wiring
Shield
Wiring
Shield
Wiring
Shield
OR

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Override Cards
For large relays or devices that cannot be powered directly from a standard
output, you will need to 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.
The following Override Cards are available from KMC Controls.
Note
Output cards must be powered with 24 VAC to enable the manual override
(HAND) function. However, this connection must not be made until the default
analog output jumper is removed.
Installing Override Boards
To install an Override Board:
1. Remove the appropriate cover from the module. The upper cover is for out-
puts 1–8 the lower for outputs 9–12.
2. Remove the jumper from the mounting header.
3. Press the override board onto the header pins. The “Hand-Off-Auto” selection
switch is always positioned toward the output connections. (Refer to Illustra-
tion 4.)
4. If required, set the selection switch on the Override Board.
Installation KMD-5831 PLC-28 Direct Digital Controller Installation & Operation Guide
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Table 1. KMD-5831 Override Board Options

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Caution
DO NOT connect active 24 VAC circuits to the output block unless the associ-
ated jumper is removed first. Doing so will result in damage to the output and
prevent it from working.
If the associated output will be an analog output, leave the jumper in place.
5. Connect output devices to the module.
6. Connect required power to the input module.
Illustration 4 gives an example of a typical output module configuration.
Using Separate Banks
The outputs are grouped into three banks that share a common switched-termi-
nal. This connection is marked as “SC” on the output block. If you connect a
circuit to this connector it then becomes common to all outputs in that bank.
Configuration
Configuration settings may be required for the inputs or the RS-485 connection.
If you must activate or deactivate pull-ups on the inputs or set the end-of-line
termination for the RS-485 connection, refer to Illustration 1 to locate the input
switches and Illustration 6 for the End-of-Line switches.
Remove jumper
before installing
board
OR
Remove jumper
prior to connecting
active 24 VAC circuits
to the associated
output terminals
Selection Switch
LED
Illustration 4. Override Board Instalaltion
KMD-5831 PLC-28 Direct Digital Controller Installation & Operation Guide Installation

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Input Pull-ups
A 10K ohm resistor is available as a pull-up to a +5 VDC source voltage for
passive or ‘dry” inputs on each input circuit. The resistor is switched “On” or
“Off” using the two dip-switches at the top of the controller. The top switch is
associated with the first 8 inputs and the lower switch is associated with the last 8
inputs. Illustration 5 shows on of these switches in greater detail.
The default setting for each input is the “On” position. In this position, the
controller will provide +5 VDC to the input device.
If the input is an active input, that is it has it’s own current source, the pull-up for
that input must be switched to the “Off” position.
End-of-Line Switches
Illustration 6 shows the position of the End-of-Line switches associated with the
RS–485 terminal. You must remove the lower blank cover to gain access to these
switches
Illustration 5. Typical Input Pull-Up Switch (1 of 2)
OFF ON
OFF ON
Illustration 6. RS–485 End-of-Line Switches
Installation KMD-5831 PLC-28 Direct Digital Controller Installation & Operation Guide
End-of-Line Switches

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Illustration 7 shows the switch in greater detail
If the controller is located at the end of the network segment the switches must
both be placed in the default “ON” position. Otherwise, place the switches in the
“OFF” position.
Power Connection
Connect the 24 VAC supply voltage to the power connectors above the RJ–11
connector on the output side of the controller. Power is applied to the controller
when the power supply (or transformer) is plugged in, as long as the Power
jumper is in place. Illustration 6 shows a typical connection diagram for the
controller.
Note:
The following guidelines apply.
◆In general, use a separate Class 2 24 VAC transformer with the smallest VA
rating that matches the specification.
◆If several controllers are mounted in the same cabinet, you can share a trans-
former between them PROVIDED the transformer does not exceed 100 VA
Configuration
Prior to operating the controller, it must be configured using the Hardware
Configuration Manager (HCM) application supplied with WinControl. Refer to
the WinControl XL User’s Manual for additional information.
Note:
All controllers on the same network must be configured for the same baud rate.
Programming
Refer to the KMC Digital Applications Manual for information on how to pro-
gram the controller.
OFF
OFF
ON
ON
Illustration 7. RS-485 End-of-Line Switch Detail
KMD-5831 PLC-28 Direct Digital Controller Installation & Operation Guide Installation

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Operation
Once configured, programmed and powered up, the controller requires very
little user intervention.
Controls and Indicators
The following sections describe the controls and indicators found on the card.
Alternately, you may remove the RS-485 terminal block from the card to isolate
the card from the network without disrupting network communications to other
controllers.
Status LEDs
Two Status LEDs are located on the bottom left side of the controller. They are
used to indicate the following:
Communications – This yellow LED flashes whenever the controller is commu-
nicating with other controllers over the RS-485 network connection.
Ready– This green LED indicates the controller has power and is operating
normally. The LED will flash on and off at one second intervals.
Isolation Lamps
Two Isolation Lamps are located below the RJ–12 connector on the right side of
the controller. These lamps serve three functions:
◆Removing the lamps will open the RS-485 circuit and isolate the controller
from the network.
◆If one, or both, lamps are lit, it indicates the network is improperly phased.
This means that the ground potential of the controller is not the same as other
controllers on the network
◆If the voltage or current on the network exceeds safe levels, the lamps operate
as fuses to protect the controller from damage.
Power Jumper
The power jumper, shown in Illustration 8, can be used to remove power from
the controller. This should be done anytime connections are made or changed on
the controller. Removing the jumper opens the 24 VAC supply circuit.
Resetting the Controller
If the controller appears to be operating incorrectly, or is not responding to
commands, you may need to reset the controller.

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Note
Resetting the controller will restore the factory default configuration. If the
devices cannot communite with the controller, or the controller cannot
commnicate with other controllers, it may be necessary to re-configure the
controller with HCM to establish normal communications and operation. Repro-
gramming may also be required.
To reset the controller, proceed as follows.
1. Remove the lower Override Board cover on the controller.
2. Locate the Reset button (see Illustration 8).
3. Locate and remove the Power Jumper from the current position.
4. Depress and hold the Reset button.
6. Reinstall the Power Jumper. (DO NOT release the Reset button.)
7. Continue to hold the Reset Button until the Communications LED flashes
rapidly.
8. Release the Reset Button.
This completes the reset sequence for the controller.
Illustration 8. RS-485 End-of-Line Switch Detail
KMD-5831 PLC-28 Direct Digital Controller Installation & Operation Guide Operation
Watch Dog
Jumper
Power
Jumper
Reset Button

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Disclaimer
The material in this document is provided for information purposes only.
The contents and the product(s) described herein 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.
Important Notices
The KMC logo is a trademark of KMC Controls, Inc.©2003, 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.
Technical Support
If you have any questions about this technical document or need additional
details, please call KMC Controls technical services at 574-831-5250 or e-
mail us at [email protected].
KMC Controls
P.O. Box 497
19476 Industrial Drive
New Paris, IN 46553
U.S.A.
TEL: [phone]
FAX: [phone]
E-mail: [email protected]
902-019-04B