TSI Instruments 8680 SUPERFLOW User manual

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TSI and TSI logo are registered trademarks of TSI Incorporated.
SureFlow is a trademark of TSI Incorporated.
MODEL 8680 SUREFLOW™
ADAPTIVE OFFSET CONTROLLER
INSTALLATION INSTRUCTIONS
WARNING: The Model 8680 Adaptive Offset Controller must be wired to 24 VAC only. Wiring the unit to
110 VAC will cause serious unit damage and void the warranty.
These installation instructions guide the installer through the installation of the TSI Model 8680 SureFlow™
Adaptive Offset Controller and all TSI options. Some options may not have been provided by TSI, so please
review those product installation instructions. Please read these instructions thoroughly before beginning
installation.
Figure 1: Typical Laboratory Installation

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Component List
NOTE: There are a large variety of options that can be installed with the Adaptive Offset Controller. The
system you are installing may not have all components or quantity of components listed below.
Only TSI-supplied devices, listed below, are covered in these installation instructions. Please refer to
the manufacturer’s installation instructions for proper installation of non TSI devices.
Adaptive Offset Controller
Part Number Qty Description
800227 1 Digital Interface Module / Adaptive
Offset Controller module (DIM /
AOC)
800326 1 Pressure sensor
800248 1 Sensor cable
800420 1 Transformer
800414 1 Transformer cable
1901057 2 Intumescent ring
2923020 1 Fire sealant
Flow Stations (each unit)
Part Number Qty Description
N/A 1 Flow station - sized to duct
(Air Monitor brand)
804139 1 Pressure Transducer (MAMAC
brand)
800420 1 Transformer
800414 2 Transformer cable - second cable is
for flow station output.
Dampers/Actuators (each unit)
Part Number Qty Description
N/A 1 Damper - sized for duct
800420 1 Transformer
800414 2 Transformer cable - second cable is
for control signal.
800360 1 Electric actuator
or
800119 1 E/P Interface
800116 1 Pneumatic operator

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Digital Interface Module Installation
1. Select the mounting location of the Digital
Interface Module (DIM). The construction plans
normally show the mounting location. If no
location is specified, the unit is typically installed
as shown in Figure 1, either in the laboratory or
in the hallway.
2. Install a standard double gang electrical box
(4” x4”).
3. Slide the DIM cover to the right and remove three
screws holding the electronics to the base
(Figure 2). Remove base.
4. Screw the base to the 4” x4” electrical box
(screws not included). The base’s “THIS SIDE UP”
arrow must be pointing towards the ceiling.
5. Refer to the wiring diagrams for proper wiring
(Figures 12 and 13). The cables are terminated
both at the DIM, and at the appropriate device.
6. Carefully push the wires into the electrical box
and mount the DIM. Re-install the three screws to
hold DIM firmly to base. Install cover and slide
left to hide display.
Figure 2: Digital Interface Module Mounting
NOTE: Two screws are hidden behind the cover when
full open. The cover will slide to the right approximately
2 inches until a stop is hit. Pull cover to completely
remove from electronics and expose the screws.
Wiring
WARNING: DO NOT connect more than
24 VAC to any terminal.
DO NOT apply voltage to the RS-485 output,
analog output, or control output. Severe
damage may occur to the unit if voltage is
applied.
WARNING: Each damper/actuator and flow
station has a separate transformer that must be
installed. DO NOT wire more than one device
per transformer.
1. Remove the connectors from the back of DIM.
2. Refer to Figures 12 and 13 wiring diagram for
pressure sensor, DIM, TSI Damper/actuator, and
TSI flow station wiring. Refer to Figure 14 wiring
diagram for transformer wiring.
NOTE: If additional options need to be wired, or
non TSI components need wiring, refer to
building prints for proper wiring diagram.
3. Strip 1/4” to 3/8” insulation from the wires.
Twist stranded wire to eliminate loose strands.
4. Insert wire into connector and tighten.
5. Insert connector into proper receptacle.

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Pressure Sensor Installation
This product is classified by Underwriters Laboratories, Inc.®for use in through-penetration
firestop systems. See UL fire resistance directory.
The pressure sensor (P/N 800326) is typically
installed above the main entrance to the laboratory
(Figure 3).
WARNING: 800326 pressure sensor must be
mounted through the wall between the controlled
space (laboratory) and referenced space
(hallway), exactly as shown in Figure 4.
1. Determine pressure sensor location (Figures 3
and 4). Pressure sensor typically mounts in the
reference space, and the dummy housing mounts
in the laboratory.
NOTE: Pressure sensor is not symmetrical. If
sensor is to be centered over hallway door,
measure one inch to the left of center for 2¼”
hole. Dummy sensor will be 2” off center on other
side of wall.
2. The pressure sensor must be orientated on the
wall as shown in Figure 5. Looking at the
mounted sensor, sensor hole is on the left
(2¼”) and wire hole is on the right.
3. Drill a 2¼-inch hole through each side of the wall
to accept the sensor tube.
4. Drill a 7/8-inch hole on the side of the wall that
the pressure sensor will be mounted. This hole is
for the six-conductor sensor cable. Refer to
Figure 5 for a hole mounting pattern.
5. Slide sensor cover to right and remove screw that
holds the sensor base to the pressure sensor
(Figure 5). Remove pressure sensor and store in a
safe place.
6. From the side of the wall the sensor will be
mounted, slide the sensor tube through the wall.
Mark the tube where it is flush with wall. Remove
sensor tube and cut tube 1/8-inch shorter than
flush marking.
Figure 3: Pressure Sensor and DIM Typical
Installation
Figure 4: Cutaway View of Mounted Pressure Sensor
NOTE: If 12” sensor tube is not long enough, add
a 1” to 2” adapter and extend with 2" OD tube.
The base of the dummy housing will need to be
drilled out to accommodate 2” tube. DO NOT
extend sensor tube with 1” tubing.
7. From the side of the wall the sensor will be
mounted, slide the sensor tube through the wall.
Slide the dummy base over the end of the tube.
Screw the pressure sensor base and dummy base
to the wall (Figure 6).

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8. Refer to the wiring diagrams for proper wiring
(Figures 12 and 13). The sensor cable is
terminated at the pressure sensor, and at the
DIM.
9. Insert fire protection sealant (provided) into 7/8”
wire hole to seal.
10. Install and screw the pressure sensor and dummy
cover onto the bases. Slide covers to the left to
hide the sensor. Finished installation should look
as shown in Figure 6.
WARNING: DO NOT touch the sensor element in
the pressure sensor. DO NOT run wires through
the air passage. Doing so will damage the sensing
element.
Figure 5: Pressure Sensor Orientation and
Mounting Template
Figure 6: Pressure Sensor Mounting

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Flow Station Installation
1. Select the mounting location of the flow station.
The construction plans normally show the
mounting location. If no location is specified, then
typically the flow station is installed upstream of
the damper actuator.
WARNING: Figure 7 gives the minimum
straight length duct diameters required for
the flow station to operate correctly.
TSI recommends installing the flow station
upstream of the damper (before). TSI does
not recommend installing the flow station
downstream (after) the damper. If the flow
station must be placed downstream, a
minimum of 4 straight duct lengths between
the damper and flow station is required. In
addition, the flow station must be rotated 90o
(perpendicular) from the damper shaft
position.
The minimum straight duct lengths shown
are the absolute minimum.
2. Drill a 1¼” hole in the side of the duct work. If
probe is longer than 18 inches, drill a 5/16" hole
directly across from the 1¼” hole (Figure 8).
3. Slide foam gasket onto flow station, and insert
into duct work. Insert the flow station through
the 1¼” hole, and into the 5/16" hole (if
required). On probes 18 inches or longer attach
the nut to the threaded end of the flow station
(5/16" hole end).
4. Rotate the flow station until the air flow indicator
arrow matches the correct direction of air flow.
5. Screw the flow station into place with sheet metal
screws (screws not provided by TSI). On 18 inch
and longer flow stations tighten the 5/16” nut.
The finished installation should look like
Figure 8.
Figure 7: Flow Station Mounting Location
Figure 8: Flow Station Hole Location

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6. Verify that the jumpers on the pressure
transducer are installed correctly, per Figure 9.
The default pressure transducer output range is
0 to 0.5 in H2O.
7. Mount the pressure transducer within 10 feet of
the flow station. The transducer must be
mounted on a wall in the correct position per
Figure 10 (screws not provided).
WARNING: DO NOT mount pressure
transducer to ceiling, duct work or vibrating
surfaces. Preferred mounting location is on the
wall nearest the flow station.
8. Run two ¼” pneumatic lines (20’ included)
between flow station and pressure transducer
and connect.
Pressure
Flow Station Transducer
Total to Hi
Static to Lo
Double check that the pneumatic tubing is
correctly plumbed, firmly seated, and has a
tight fit.
9. Refer to the wiring diagrams for proper wiring
(Figures 12 and 13). The cable is terminated at
the pressure transducer and at the DIM.
Figure 9: Pressure Transducer Jumpers
Figure 10: Pressure Transducer Mounting

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TSI Damper/Actuator Installation
WARNING: Building prints normally determine damper location and mounting configuration. They
supersede the guidelines below.
1. The actuators are shipped mounted to the damper. No adjustments are needed prior to mounting
the assembly.
2. The damper must be installed with the damper shaft parallel to the ground (Figure 12).
3. Slip-fit dampers mount INSIDE the ductwork. Flanged dampers bolt to the duct work. No ductwork can be
inside of dampers or interfere with damper rotation.
4. Rivet slip-fit damper to ductwork to ensure damper rotates correctly. Alternate: Use 1-inch or shorter
screws. Make sure screws DO NOT interfere with damper blade rotation; damper rotates outside of
damper sleeve. Bolt flanged dampers securely to ductwork but DO NOT “force” damper to fit
(deforms damper).
5. Pneumatic version require installing a:
¼-inch pneumatic line between E/P and actuator (motor).
20 PSI (30 PSI maximum) ¼-inch pneumatic line to the E/P.
6. Refer to the wiring diagrams for proper wiring (Figures 12 and 13). The cable is terminated at the
damper/actuator and at the DIM.
Figure 11: Proper Damper Mounting

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WARNING: Controller must be wired exactly as wire diagram shows. Making modifications
to the wiring may severely damage the unit.
Figure 12: Diagram –Electric Actuator Version

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WARNING: Controller must be wired exactly as wire diagram shows. Making modifications
to the wiring may severely damage the unit.
Figure 13: Wiring Diagram –Pneumatic Actuator Version

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Transformer Installation
Transformers are provided for the DIM/AOC, each damper/actuator, and each flow station (TSI). Thermostat
manufacturer provides transformer to power thermostat.
WARNING: Each damper/actuator and flow station has a separate transformer that must be installed.
DO NOT wire more than one device per transformer.
Figure 14: Transformer Installation
WARNING:
Make sure no power is applied until all
wiring is complete.
Follow all applicable electrical codes,
and have qualified personnel install
the transformer.
NOTE: 115 Volt, single phase, 60 Hertz
power source is required to power the
800420 transformer. If TSI Transformer is
not installed, a regulated 24 Volt, single
phase, 60 Hertz power source is required
to power the controller.
1. Mount a standard 4" x4" x1½" electrical box at a convenient location within 20 feet (transformer cable is
25’ long) of the device being installed; Adaptive Offset Controller, damper/actuator, or flow station. Each
device must have a separate transformer. DO NOT INSTALL MULTIPLE DEVICES ON ONE
TRANSFORMER.
2. Run 115 Volt, single phase, 60 hertz line voltage (115 VAC) to transformer electrical box. Follow all
applicable electrical codes.
3. Connect 115 VAC line voltage HOT wire to BLACK wire on transformer and NEUTRAL wire to WHITE wire
on transformer (Figure 14).
4. Connect the RED wire on 800414 transformer cable to either of the YELLOW wires on the transformer and
the BLACK wire to the remaining YELLOW wire.
5. Screw the transformer to the electrical box.
6. Run transformer cable from the transformer electrical box to the device. Have at least 8 inches of extra
cable at the device before trimming cable to length. Wire devices per Figures 12 and 13.
If you need assistance installing the system, call TSI Customer Service at 651-490-2811 or 800-874-2811.