TSI Instruments SUREFLOW 8681 User manual

_____________________

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

Page 2 of 12

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

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

Page 3 of 12

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.

Page 4 of 12

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.

Page 5 of 12

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

Page 6 of 12

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

Page 7 of 12

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

Page 8 of 12

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

Page 9 of 12

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

Page 10 of 12

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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