KMC Controls SimplyVAV BAC-8001 User manual

Installation Guide
Cooling Only BAC-8001
BacNet DDC VAV Controller

2
BAC-8001 VAV Controller
Contents
Section 1
About the controllers
Specifications ........................................................................................................................5
Safety considerations .......................................................................................................... 7
Section 2
Installing the controllers
Setting the rotation limits ................................................................................................. 9
Mounting ............................................................................................................................ 10
Connecting inputs ............................................................................................................. 11
Connecting outputs ........................................................................................................... 12
Connecting to sensors ....................................................................................................... 12
Connecting to an MS/TP network .................................................................................. 13
Connecting an airflow sensor .......................................................................................... 16
Connecting power ............................................................................................................. 17
Application drawing ......................................................................................................... 18
Section 3
Setting up VAV controllers
Network communications ................................................................................................ 19
Setting temperature setpoints .......................................................................................... 20
Setting airflow setpoints ................................................................................................... 21
Setting the VAV terminal unit parameters .................................................................... 21
Balancing airflow ............................................................................................................... 21

3
SECTION 1
About the controllers
This section provides a description of the BacNet DDC
BAC-8001 VAV controllers. It also introduces safety information.
Review this material before installing or operating the controllers.
The BAC-8001 is native BACnet, direct digital controllers designed for VAV
terminal units. An integrated actuator and the supplied programs make these
ideal controllers for basic single-duct cooling and heating applications. Install
these versatile controllers in stand-alone environments or networked to other
BACnet devices. As part of a complete facilities management system, the
BAC-8001 controller providesprecise monitoring and control of connected
points.
BACnet MS/TP compliant
Standard VAV control sequences are incorporated to provide pressure
independent control of VAV unit
On-board airflow sensor for use with a single or multi-point differential
pressure measuring station or pitot tube.
Specifications
Analog inputs All inputs are configured as analog objects
Active inputs 1
Passive inputs 3
Air flow sensor 1
Key features Standard units of measure.
Overvoltage input protection
Connector Spade connectors, 0.25 inch
Conversion 12–bit analog–to–digital conversion
Input range 0–12 volts DC
Outputs, binary 2 for the internal actuator
Key features
Conversion 12–bit analog–to–digital conversion
Connector Spade connectors, 0.25 inch
Output range Maximum switching 24 VAC at 3 amperes

About the controllers
Specifications
4
Communications
BACnet MS/TP EIA–485 operating at rates up to 76.8 kilobaud.
Removable screw terminal block.
Wire size 12–24 AWG
Sensor jack RJ-45 jack compatible with model STE-8000 and
STE-6000 models with RJ-45 jacks
Supported objects See PIC statement for supported BACnet objects
Control Basic 5 program areas in BAC-8001
6 program areas in BAC-8201
PID loop objects 2
Value objects 60 analog, 32 binary, and 12 multistate
MemoryPrograms and program parameters are stored in
nonvolatile memory.
Auto restart on power failure
Application programs
Cooling and heating VAV
Balancing
UL 864 smoke controll (BAC-8201 only)
Air flow sensor features Configured as BACnet analog input object.
CMOS differential pressure 0-2 inches of water
(0-500 Pa) measurement range. Internally
linearized and temperature compensated.
Span accuracy 4.5% of reading.
Barbed connections for 1/4 FR tubing.
Range dependent upon DP pickup, tubing size/
length and connections.
Actuator specifications
Torque 40 in-lb. (4.5 N•m)
Angular rotation 0 to 95°
Adjustable end stops at 45° and 60° rotation
Motor timing, BAC-8001 90 sec./90° at 60 Hz
108 sec./90° at 50 Hz
Motor timing, BAC-8201 60sec./90° at 60 Hz
72 sec./90° at 50 Hz
Shaft size Directly mounts on 3/8 to 5/8 inch (9.5 to 16 mm)
round or 3/8 to 7/16 inch (9.5 to 11 mm) square
damper shafts.
Titus Alpha Controls supplies models BAC-8001
and BAC-8201 with programming sequences for
single-duct VAV applications.

BAC-8001 and BAC-8201 VAV Controllers About the controllers
Specifications
5
Regulatory UL 916 Energy Management Equipment
FCC Class B, Part 15, Subpart B
BACnet Testing Laboratory listed as an application
specific controller (ASC).
UL 864 smoke controls (BAC-8201 only)
Installation
Supply voltage 24 volts AC, -15%, +20% 5 VA
Weight 13.2 ounces (376 grams)
Case material Flame retardant plastic
Environmental limits
Operating32 to 120°F (0 to 49° C)
Shipping –40 to 140° F (–40 to 60° C)
Humidity 5–95% relative humidity (non-condensing)
Models
BAC-8001 VAV controller with 90 second actuator and reheat
BAC-8201 VAV controller with 60 second actuator, reheat,
and UL 864 smoke control application

About the controllers
Specifications
6
Dimensions
Table 1-1 BAC-8000 dimensions
ABCD EFG
6.53 in.4.89 in.4.25 in.0.77 in.6.00 in.2.14 in.1.92 in.
166 mm 124 mm 108 mm 19 mm 152 mm 54 mm 49 mm
A
B
D
G
F
E
C

About the controllers
Safety considerations
7
Safety
considerations
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.
Titus 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.

8
SECTION 2
Installing the controllers
This section provides important instructions and guidelines for
installing the BAC-8001 controller. Carefully review this
information before installing the controllers.
Installing a VAV controller includes the following topics that are covered in this
section.
Setting the rotation limits on page 12
Mountingon page 13
Connecting inputs on page 14
Connecting outputs on page 15
Connecting to an MS/TP network on page 16
Connecting an airflow sensor on page 19
Connecting power on page 20
In addition to the topics, see the section Application drawing on page 21.

Installing the controllers
Setting the rotation limits
9
Setting the
rotation limits Before mounting the controller, set the rotation limits with the supplied stop
screw. Installing the stop screw limits the shaft rotation to either 45 or 60 degrees.
Caution
Before setting the rotation limits on the controller, refer to the damper position
specifications in the VAV control box to which the controller will be attached.
Setting rotation limits that do not match the VAV damper may result in
improper operation or equipment damage.
To set the rotational limits:
1. Turn the controller over so you have access to the back.
2. Manually rotate the actuator fully clockwise as viewed from the back.
3. Remove the stop screw from its storage location and clean any debris from
the threads.
4. Insert the screw into the correct stop position hole.
5. Tighten the screw only until the head touches the plastic in the bottom of
the recess.
Illustration 2-1 Controller stop selections
Stop position
holes
Stop screw
in storage
Rotate CW
Position notch
as shown

BAC-8001 and BAC-8201 VAV Controllers Installing the controllers
Mounting
10
Mounting Mount the controller inside of a metal enclosure. To maintain RF emissions
specifications, use either shielded connecting cables or enclose all cables in
conduit.
Mount the controller directly over the damper shaft. A minimum shaft length of
2.0 inch (51 mm) is required.
Note
.
Mount the controller close enough to the pitot tubes to keep the tubing length to
a minimum. In typical installations the controller’s inputs and sensors are within
24 inches of each other.
Mount the controller as follows:
1. Loosen the nuts on the U-bolt until the shaft can fit through the collar.
2. Place the controller on the damper shaft in the approximate final position.
Position the controller loosely against the mounting surface so that the
mounting bushing can float freely in the mounting tab.
3. Center the mounting bushing in the slot of the mounting tab and secure it
using a #8 self-tapping screw.
4. Manually position the damper in the full open position.
5. Adjust the drive hub as follows:
a. If the damper rotates counter clockwise to close, depress the gear
disengagement button and rotate the drive hub to the full clockwise
position then release the button.
b. If the damper rotates clockwise to close, depress the gear disengagement
button and rotate the drive hub to the full counter clockwise position
then release the button.
6. Lock the hub to the shaft by evenly tightening the V-bolt nuts to 30 to 35
in-lbs.
Illustration 2-2 Controls and indicators
Mounting tab
Gear disengagement button
Airflow sensor inputs
Drive hub
and V-bolt
Status LEDs
Mounting bushing
The controller is designed to directly mount to 3/8 to 5/8 inch (9.5 to 16mm)
round or 3/8 to 7/16 (9.5 to 11mm) square damper shafts.

Installing the controllers
Connecting inputs
11
Connecting
inputs The BAC-8001 controller haspreconfigured analog inputs to support the
supplied programs. The inputs cannot be changed to binary or accumulator
inputs. Only one input has an externally available physical terminal. All of
the inputs are preconfigured for the application programs supplied in the
controllers and are listed in Table 2-1.
Discharge air temperature Connect a 10k, Type 3 thermistor temperature probe
to the discharge air temperature input. The input includes the internal pull-up
resistor. An STE-1405 sensor is suitable for this application. Follow the
instructions supplied with the sensor for installation. See Setting temperature
setpoints on page 30 for setting up discharge air temperature limiting that requires
this input sensor.
Space Temperature Input The space temperature input is connected only
through the RJ-45 thermostat and sensor input jack. It is a configured as an
analog input for STE-6010, STE-6014, and STE-6017 sensors. If an STE-8000
sensor is connected to the controller, this input is ignored. See Connecting to
sensors on page 15.
Space Setpoint The space setpoint input is connected only through the RJ-45
thermostat and sensor input jack. It is a configured for the setpoint dials on
STE-6014 or STE-6017 sensors. If an STE-6010 or STE-8000 sensor is connected to
the controller, this input is ignored. See Connecting to sensors on page 15.
Primary Duct Pressure The primary duct pressure input is an internal
measurement from the airflow sensor.
Primary Damper Position (BAC-8201 only) The primary damper position input
is preconfigured as an analog input that represents the position of the internal
damper.
Table 2-1 BAC-8001 and BAC-8201 input objects
Object Function Name Unit Location Pull up
AI1Discharge Air Temperature DISCHARGE AIR °F Terminal block10k
AI2Space Sensor SPACE SENSOR °F RJ-45 10k
AI3Space Setpoint SPACE SETPOINT °F RJ-45 10k
AI4Primary Duct Pressure PRIMARY DUCT wc Internal airflow sensorN/A
AI5Primary Damper PositionPRIMARY POSITION Volts Internal damper position N/A
Illustration 2-3 Discharge air temperature

BAC-8001 and BAC-8201 VAV Controllers Installing the controllers
Connecting outputs
12
Connecting
outputs The BAC-8001 controller hastwo preconfigured outputs to support the
supplied programs. The outputs are programmed run the integrated actuator in
either a clockwise or counterclockwise direction. No external output
connections are available.
Connecting to
sensors Connect any of the following sensors to the RJ-45 thermostat and sensor jack.
STE-8001
STE-8201
STE-6010
STE-6014
STE-6017
Link the controller to sensors with standard straight-through Ethernet cables up
to 75 feet long. See the installation guide supplied with the sensors for complete
sensor installation instructions.
No programming or configuration is required for the supported sensors. The
controller is configured to automatically detect which type of sensor is
connected to it.
Table 2-2 BAC-8001 output objects
Object Function Name False
valueTrue value Default
valueTy pe
BO1 Damper Clockwise DAMPER CW NeutralClockwise NeutralInternal
BO2 Damper Counter
Clockwise
DAMPER CCW Neutral Counterclockwise NeutralInternal
Illustration 2-4 Connecting to a sensor
Maximum 75 feet v
Sensor jack

Installing the controllers
Connecting to an MS/TP network
13
Connecting to an
MS/TP network The BAC-8000 series controllers are BACnet MS/TP compliant controllers.
Connect them only to a BACnet MS/TP network.
See Application Note AN0404A, Planning BACnet Networks for additional
information about installing controllers.
Connections and wiring
Use the following principles when connecting a controller to an MS/TP
network:
Connect no more than 128 addressable BACnet devices to one MS/TP
network. The devices can be any mix of controllers or routers.
To prevent network traffic bottlenecks, limit the MS/TP network size to 60
controllers.
Use 18 gauge, twisted pair, shielded cable with capacitance of no more than
51 picofarads per foot for all network wiring. Belden cable model #82760
meets the cable requirements.
Connect the -Aterminal in parallel with all other - terminals.
Connect the +Bterminal in parallel with all other + terminals.
Connect the shields of the cable together at each controller. For KMC
BACnet controllers use the Sterminal.
Connect the shield to an earth ground at one end only.
Use a KMD–5575 repeater between every 32 MS/TP devices or if the cable
length will exceed 4000 feet (1220 meters). Use no more than four repeaters
per MS/TP network.
Place a KMD–5567 surge surpressor in the cable where it exits a building.
Illustration 2-5 MS/TP network connection
S +B -A

BAC-8001 and BAC-8201 VAV Controllers Installing the controllers
Connecting to an MS/TP network
14
Note
The MS/TP terminals are labeled -A, +B and S. The Sterminal is provided as a
connecting point for the shield. The terminal is not connected to the ground of
the controller. When connecting to controllers from other manufacturers, verify
the shield connection is not connected to ground.
Illustration 2-6 MS/TP network wiring
Redundant network
wiring for increased
reliability
Ground shield only at
one end of the segment.

Installing the controllers
Connecting to an MS/TP network
15
End of line termination switches
The controllers on the physical ends of the EIA-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.
Illustration 2-8 shows the position of the BAC-8000 End-of-Line switches
associated with the MS/TP inputs.
Illustration 2-7 End of line termination
Illustration 2-8 Location of EOL switch
Set end-of-line termination to
On in these controllers only.
On
Off

BAC-8001 and BAC-8201 VAV Controllers Installing the controllers
Connecting an airflow sensor
16
Connecting an
airflow sensor An airflow sensor is incorporated as one of the inputs to the controller. Remove
the plugs and connect the tubing from the pitot assembly to the airflow sensor
inputs next to the drive hub. (See Illustration 2-9). The airflow sensor is
programmed as Input 4.
Illustration 2-9 Airflow sensor inputs
Total airflow (high) Static airflow (low)

Installing the controllers
Connecting power
17
Connecting
powerThe controllers require an external, 24 volt, AC power source. Use the following
guidelines when choosing and wiring transformers.
.
Do not run 24 volt, AC power from within an enclosure to external
controllers.
Connect the 24 volt AC power supply to the power terminal block on the lower
right side of the controller near the power jumper. Connect the ground side of
the transformer to the ground terminal and theAC phase to the phase ~
terminal. Power is applied to the controller when the transformer is powered.
Illustration 2-10 Power terminals and jumper
Illustration 2-11 Power connections
Power
terminals
Use a Titus Alpha Controls Class-2 transformer of the appropriate size to supply
power to the controllers. Titus recommends powering only one controller from each
transformer.

BAC-8001 and BAC-8201 VAV Controllers Installing the controllers
Application drawing
18
Application
drawing The BAC-8001 controller is configured by the manufacturer for single-duct
cooling or heating VAV control. Connect the controller as shown in the
illustration BAC-8001 application on page 21.
Illustration 2-12 BAC-8001 application

19
SECTION 3
Setting up VAV controllers
The topics in this section cover setting up the BAC-8001
controller for VAV operation. These are advanced topics for
controls technicians and engineers.
The BAC-8001 VAV controller is set up by the manufacturer to operate as soon
as they are connected to external equipment and power is applied. Installation
and connection instructions are covered in the section Installing the controllers on
page 11.
Setting up the controllers may include setting BACnet objects with a BACnet
Operator Workstation such as TotalControl. The objects may also be set up with
an STE-8001 or STE-8201 sensor. The following topics are covered in this section.
Setting temperature setpoints on page 24
Setting airflow setpoints on page 25
Setting the VA V terminal unit parameters on page 25
Network communications on page 23
Caution
Change only the present values of the objects listed in this section. Changing
any other objects or properties will result in improper operation.
Network
communications Before connecting the controller to a BACnet MS/TP network, configure the
following network parameters with either a BACnet operator workstation or
temporarily connecting an STE-8001 or STE-8201 to the controller.
Device instance—Set from 0 to 4,194,302. A device instance number must
be unique across the BACnet internetwork.
Baud—Valid baud settings are 9600, 19200, 38400, and 76800.
MAC—Set from 0 to 127. Must be unique on the MS/TP network to which
the controller is connected.

Setting up VAV controllers
Setting temperature setpoints
20
Setting
temperature
setpoints The space temperate setpoints listed in Table 3-1, “Temperature setpoints,” on
page 24 are used to control the controller VAV operation. The temperature
setpoints have default values, but may be manipulated depending on which
type of wall sensor is connected to the controller.
Occupied cooling and heating setpoints These setpoints are user controlled
space setpoints that originate from an attached sensor. If no sensor is attached
the values for these setpoints are manually entered by a controls technician.
Unoccupied cooling and heating setpoints The unoccupied setpoints are
manually entered values to set the heating and cooling temperature when the
space is unoccupied.
Minimum cooling setpoint A manually entered value to limit the occupied
cooling setpoint regardless of the value entered by the user.
Maximum heating setpoint A manually entered value to limit the occupied
heating setpoint regardless of the value entered by the user.
Minimum setpoint differential Sets the minimum temperature separation
between occupied heating and cooling setpoints.
Standby differential This differential is added or subtracted from the occupied
temperature setpoints to calculate the standby setpoints.
SAT changeover temperature Sets the supply air temperature at which the
controller will change from heating to cooling. The changeover takes place when
the supply air temperature is 2° above or below the discharge air temperature
setpoint.
Table 3-1 Temperature setpoints
Object Description Name Default
AV5Occupied Cooling Setpoint OCC CL STPT 74°F
AV6Occupied Heating Setpoint OCC HT SPT70°F
AV7Unoccupied Cooling Setpoint UNOCC CL STPT 80°F
AV8Unoccupied Heating Setpt UNOCC HT STPT 64°F
AV9Minimum Cooling Setpt MIN CL STPT 70°F
AV10 Maximum Heating Setpoint MAX HT STPT 76°F
AV11 Minimum Setpoint DifferentialMIN STPT DIFF 4°F
AV12 Standby Differential STBY DIFF 3°F
AV37 SAT Changeover Temp SAT CHANGEOVER 75°F