TSI Instruments SUREFLOW 8681 User manual

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TSI and TSI logo are registered trademarks of TSI Incorporated.
SureFlow is a trademark of TSI Incorporated.
MODEL 8681 SUREFLOW™
ADAPTIVE OFFSET CONTROLLER
INSTALLATION INSTRUCTIONS
WARNING: The Model 8681 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 8681 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.
Overview
Figure 1 provides an overview of the various components installed. The order the components are installed is
not important. The building prints will define the location of the dampers, flow stations, and pressure sensor. If
no location is defined, these instructions show “typical” installation locations.
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 or 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
800776 1 Digital Interface Module /
Adaptive Offset Controller
(DIM / AOC) with MODBUS
or
868128 1 Digital Interface Module /
Adaptive Offset Controller
(DIM / AOC) with BACnet
MSTP
800326 1 Pressure sensor (Not on
Offset-only controllers)
800248 1 Sensor cable
800420 1 Transformer
800414 1 Transformer cable
1901057 2 Intumescent ring
2923020 1 Fire sealant
800893 1 1000 platinum RTD
Flow Stations (Each Unit)
Part Number Qty Description
NONE 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
None 1 Damper - sized for duct
800420 1 Transformer
800414 2 Transformer cable - second
cable is for control signal.
800370 1 Electric actuator

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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, then 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.

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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 ¼” 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,
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.
Figure 3: Pressure Sensor and DIM
Typical Installation
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8inch
shorter than flush marking.
Figure 4: Cutaway View of Mounted
Pressure Sensor

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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).
8) Refer to the wiring diagrams for proper wiring
(Figures 12). 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).
Figure 7: Flow Station Mounting Location
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 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, ductwork 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.
Flow Station Pressure
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.
WARNING: Do not mount pressure
transducer to ceiling, ductwork or vibrating
surfaces. Preferred mounting location is on
the wall nearest the flow station.
Figure 9: Pressure Transducer Jumpers
Figure 10: Pressure Transducer Mounting

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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 11).
3) Slip-fit dampers mount INSIDE the duct work. 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 duct work to ensure damper rotates correctly. Alternate: use 1-inch or shorter
screws. Make sure screws do not interfere with damper blade rotation; damper blade rotates outside of
damper sleeve. Bolt flanged dampers securely to ductwork, but do not “force” damper to fit
(deforms damper).
5) 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: Adaptive Offset Wiring 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: Offset (Flow Tracking) Wiring Diagram –Electric Actuator Version

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Transformer Installation
Transformers are provided for the DIM/AOC, each damper/actuator, and each flow station (TSI).
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.
NOTE: If you need assistance installing the system, call TSI Customer Service at [phone].