Models 8681/8681_BAC SureFlow Adaptive Offset Controller

Models 8681/8681_BAC SureFlow Adaptive Offset Controller
SUREFLOW™
ADAPTIVE OFFSET CONTROLLER
MODELS 8681
8681-BAC
OPERATION AND SERVICE MANUAL
P/N 1980476, REVISION E
FEBRUARY 2013
SUREFLOW™
ADAPTIVE OFFSET CONTROLLER
MODELS 8681
8681-BAC
OPERATION AND SERVICE MANUAL
P/N 1980476, REVISION E
FEBRUARY 2013
U.S. AND CANADA
Sales & Customer Service:
(800) 874-2811/(651) 490-2811
Fax:
(651) 490-3824
SHIP/MAIL TO:
TSI Incorporated
ATTN: Customer Service
500 Cardigan Road
Shoreview, MN 55126
USA
OTHER COUNTRIES
Sales & Customer Service:
(001 651) 490-2811
Fax:
(001 651) 490-3824
E-MAIL
[email protected]
WEB SITE
www.tsi.com
Copyright - TSI Incorporated / 2010-2013 / All rights reserved.
Part number 1980476 Rev. E
LIMITATION OF WARRANTY AND LIABILITY (effective June 2011)
Seller warrants the goods sold hereunder, under normal use and service as described in the operator's manual,
shall be free from defects in workmanship and material for 24 months, or if less, the length of time specified in
the operator's manual, from the date of shipment to the customer. This warranty period is inclusive of any
statutory warranty. This limited warranty is subject to the following exclusions and exceptions:
a. Hot-wire or hot-film sensors used with research anemometers, and certain other components when indicated
in specifications, are warranted for 90 days from the date of shipment;
b. Pumps are warranted for hours of operation as set forth in product or operator’s manuals;
c. Parts repaired or replaced as a result of repair services are warranted to be free from defects in workmanship
and material, under normal use, for 90 days from the date of shipment;
d. Seller does not provide any warranty on finished goods manufactured by others or on any fuses, batteries or
other consumable materials. Only the original manufacturer's warranty applies;
e. Unless specifically authorized in a separate writing by Seller, Seller makes no warranty with respect to, and
shall have no liability in connection with, goods which are incorporated into other products or equipment, or
which are modified by any person other than Seller.
The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS stated herein. NO OTHER
EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR PARTICULAR PURPOSE OR MERCHANTABILITY
IS MADE. WITH RESPECT TO SELLER’S BREACH OF THE IMPLIED WARRANTY AGAINST
INFRINGEMENT, SAID WARRANTY IS LIMITED TO CLAIMS OF DIRECT INFRINGEMENT AND
EXCLUDES CLAIMS OF CONTRIBUTORY OR INDUCED INFRINGEMENTS. BUYER’S EXCLUSIVE
REMEDY SHALL BE THE RETURN OF THE PURCHASE PRICE DISCOUNTED FOR REASONABLE WEAR
AND TEAR OR AT SELLER’S OPTION REPLACEMENT OF THE GOODS WITH NON-INFRINGING
GOODS.
TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER OR BUYER, AND THE
LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES, INJURIES, OR DAMAGES CONCERNING THE
GOODS (INCLUDING CLAIMS BASED ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR
OTHERWISE) SHALL BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE
PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR REPLACEMENT OF THE GOODS. IN THE
CASE OF SOFTWARE, SELLER WILL REPAIR OR REPLACE DEFECTIVE SOFTWARE OR IF UNABLE TO
DO SO, WILL REFUND THE PURCHASE PRICE OF THE SOFTWARE. IN NO EVENT SHALL SELLER BE
LIABLE FOR LOST PROFITS OR ANY SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER
SHALL NOT BE RESPONSIBLE FOR INSTALLATION, DISMANTLING OR REINSTALLATION COSTS OR
CHARGES. No Action, regardless of form, may be brought against Seller more than 12 months after a cause of
action has accrued. The goods returned under warranty to Seller's factory shall be at Buyer's risk of loss, and will
be returned, if at all, at Seller's risk of loss.
Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY AND LIABILITY, which
contains the complete and exclusive limited warranty of Seller. This LIMITATION OF WARRANTY AND
LIABILITY may not be amended, modified or its terms waived, except by writing signed by an Officer of Seller.
SERVICE POLICY
Knowing that inoperative or defective instruments are as detrimental to TSI as they are to our customers, our
service policy is designed to give prompt attention to any problems. If any malfunction is discovered, please
contact your nearest sales office or representative, or call TSI's Customer Service department at (800) 8742811.
TRADEMARKS
TSI and TSI logo are registered trademarks of TSI Incorporated.
SureFlow is a trademark of TSI Incorporated.
LonWorks is a registered trademark of Echelon® Corporation.
BACnet is a registered trademark of ASHRAE.
Microsoft is a registered trademark of Microsoft Corporation.
ii
CONTENTS
HOW TO USE THIS MANUAL ...................................................................................................... IV
PART ONE .......................................................................................................................................1
User Basics ............................................................................................................1
The Instrument .......................................................................................................1
Operator Panel .......................................................................................................3
Alarms.....................................................................................................................5
Before Calling TSI ..................................................................................................7
PART TWO.......................................................................................................................................9
Technical Section ...................................................................................................9
Software Programming ...........................................................................................9
Menu and Menu Items ..........................................................................................14
Setup / Checkout ..................................................................................................47
Calibration ............................................................................................................55
Maintenance and Repair Parts .............................................................................59
APPENDIX A ..................................................................................................................................61
Specifications .......................................................................................................61
APPENDIX B ..................................................................................................................................63
Network Communications ....................................................................................63
Modbus Communications .....................................................................................63
8681 BACnet® MS/TP Protocol Implementation Conformance Statement ..........67
Model 8681-BAC BACnet® MS/TP Object Set .....................................................69
APPENDIX C ..................................................................................................................................71
Wiring Information ................................................................................................71
APPENDIX D ..................................................................................................................................75
Access Codes.......................................................................................................75
iii
How to Use This Manual
The SureFlow Operation and Service Manual is divided into two parts. Part one describes how
the SureFlow unit functions and how to interface with the device. This section should be read by
users, facilities staff, and anyone who requires a basic understanding of how the SureFlow
controller operates.
Part two describes the technical aspects of the product which includes operation, calibration,
configuration, and maintenance. Part two should be read by personnel programming or
maintaining the unit. TSI recommends thoroughly reading this manual before changing any
software items.
NOTE: This operation and service manual assumes proper SureFlow controller installation.
Refer to the Installation Instructions to determine if the SureFlow controller has been
properly installed.
iv
PART ONE
User Basics
Part one provides a brief but thorough overview of the SureFlow product by maximizing
information with minimal reading. These few pages explain the purpose (The Instrument), and the
operation (Useful User Information, Digital Interface Module, Alarms) of the unit. Technical
product information is available in Part Two of the manual. The manual focuses on laboratory
spaces; however, the information is accurate for any room pressure application.
The Instrument
The SureFlow Adaptive Offset Controller (AOC) maintains laboratory pressure and air balance.
The AOC measures and controls all airflow into and out of the laboratory, and measures the
pressure differential. Proper laboratory pressure differential provides safety by controlling
airborne contaminants that can adversely affect workers in the laboratory, people in the
laboratory vicinity, and experiments. For example, laboratories with fume hoods have negative
room pressure (air flowing into the room), to minimize exposure to people outside the laboratory.
The fume hood is the first level of containment, and the laboratory space is the second level of
containment.
Room pressure, or pressure differential, is created when one space (hallway) is at a different
pressure than an adjoining space (laboratory). The Adaptive Offset Controller (AOC) creates a
pressure differential by modulating supply air into and exhaust air out of the laboratory (hallway
space is a constant volume system). The theory is that if more air is exhausted out than is
supplied, the laboratory will be negative compared to the hallway. A set offset may not maintain
an adequate pressure differential under all conditions. The AOC compensates for the unknown
pressure differential by mounting a pressure differential sensor between the hallway and
laboratory that confirms correct pressure differential is being maintained. If pressure is not being
maintained, the AOC modulates the supply or exhaust air until pressure is maintained.
Negative
Positive
Figure 1: Room Pressure
Negative room pressure is present when air flows from a hallway into the laboratory. If air flows
from the laboratory into the hallway, the room is under positive pressure. Figure 1 gives a graphic
example of positive and negative room pressure.
An example of negative pressure is a bathroom with an exhaust fan. When the fan is turned on,
air is exhausted out of the bathroom creating a slight negative pressure when compared to the
hallway. This pressure differential forces air to flow from the hallway into the bathroom.
User Basics
1
The SureFlow device informs the laboratory users when the laboratory is under proper pressure,
and provides alarms when the room pressure is inadequate. If the room pressure is in the safe
range, a green light is on. If the pressure is inadequate, a red alarm light and audible alarm turn
on.
The SureFlow controller consists of two pieces: a pressure sensor, and Digital Interface Module
(DIM) / Adaptive Offset Controller (AOC). The AOC is internally part of the DIM module. The
components are typically located as follows; pressure sensor above the laboratory entrance, DIM
/ AOC is mounted close to the entrance to the laboratory. The pressure sensor continuously
measures the room pressure and provides room pressure information to the DIM / AOC. The DIM
/ AOC continuously reports the room pressure and activates the alarms when necessary. The
DIM / AOC controls the supply and exhaust dampers to maintain the pressure differential. The
DIM / AOC is a closed loop controller that is continuously measuring, reporting, and controlling
room pressure.
Useful User Information
The DIM has a green light and red light to indicate room pressure status. The green light is on
when the room has proper room pressure. The red light comes on when an alarm condition
exists.
Sliding the door panel to the right reveals a digital display and keypad (Figure 2). The display
shows detailed information about room pressure, alarms, etc. The keypad allows you to test the
device, put the device into emergency mode, and program or change the device parameters.
Figure 2: Digital Interface Module (DIM)
SureFlow controller has two levels of user information:
1.
SureFlow controller has a red light and green light to provide continuous
information on room pressure status.
2.
SureFlow controller has a hidden operator panel providing detailed room status
information, self-testing capabilities, and access to the software programming
functions.
NOTE: The unit provides continuous room pressure status through the red and green light. The
operator panel is normally closed unless further information on room pressure status is
needed, or software programming is required.
2
Part One
Operator Panel
The DIM in Figure 3 shows the location of the digital display, keypad and lights. An explanation of
the operator panel follows the figure.
Figure 3: SureFlow Operator Panel - Open
Green / Red Light
The green light is on when all the conditions for proper room pressure are adequate. This light
indicates the laboratory is operating safely. If any of the room pressure conditions cannot be
satisfied, the green light turns off and the red alarm light turns on.
Operator Panel
A cover hides the operator panel. Sliding the door panel to the right exposes the operator panel
(Figure 2).
Digital Display
The alphanumeric digital display is a two-line display that indicates actual room pressure (positive
or negative), alarm status, menu options, and error messages. In normal operation (green light is
on), the display indicates information about room pressure. If an alarm condition occurs, the
display changes from
STANDARD
NORMAL
to read
STANDARD
ALARM = *
* states type of alarm; low pressure, high pressure, flow
When programming the unit, the display changes and now shows menus, menu items, and
current value of the item, depending on the specific programming function being performed.
NOTE: The AOC system controls room pressure without a pressure sensor installed. However,
verification that room pressure is being maintained is not possible. The display will not
indicate room pressure or room pressure status when no pressure sensor is installed.
The alarms can be programmed to indicate when low supply or exhaust flow is present.
Keypad
The keypad has six keys. The gray keys with black letters are user information keys. In normal
operation these keys are active. Additionally, the red emergency key is active. The gray keys with
blue characters are used to program the unit. A thorough description of each key is given on the
next two pages.
User Basics
3
User Keys - Gray with Black Letters
The four keys with black letters provide you information without changing the operation or the
function of the unit.
TEST Key
The TEST key initiates an instrument self-test. Pressing the TEST key activates a
scrolling sequence on the display that shows the product model number, software
version, and all setpoint and alarm values. The unit then performs a self-test that tests
the display, indicator lights, audible alarm, and internal electronics to ensure they are
operating properly. If a problem with the unit exists, DATA ERROR is displayed. You
should have qualified personnel determine the problem with the unit.
RESET Key
The RESET key performs three functions. 1) Resets the alarm light, alarm contacts, and
audible alarm when in a latched or non-automatic reset mode. The DIM must return to
the safe or normal range before the RESET key will operate. 2) Resets the emergency
function after the emergency key has been pressed (see EMERGENCY key). 3) Clears
any displayed error messages.
MUTE Key
The MUTE key temporarily silences the audible alarm. The time the alarm is temporarily
silenced is programmable by you (see MUTE TIMEOUT). When the mute period ends,
the audible alarm turns back on if the alarm condition is still present.
NOTE: You can program the audible alarm to be permanently turned off (see AUDIBLE
ALM).
AUX Key
The AUX key is active only in specialty applications and is not used on the standard
SureFlow controller. If the AUX key is used, a separate manual supplement explains the
AUX key function.
Programming Keys - Gray with Blue Characters
The four keys with blue print are used to program or configure the unit to fit a particular
application.
WARNING:
Pressing these keys changes how the unit functions, so please thoroughly review
the manual before changing menu items.
MENU Key
The MENU key performs three functions. 1) Provides access to the menus when in the
normal operating mode. 2) When the unit is being programmed, the MENU key acts as
an escape key to remove you from an item or menu, without saving data. 3) Returns the
unit to the normal operating mode. The MENU key is further described in the Software
Programming section of this manual.
SELECT Key
The SELECT key performs three functions. 1) Provides access to specific menus.
2) Provides access to menu items. 3) Saves data. Pressing the key when finished with a
menu item saves the data, and exits you out of the menu item.
4
Part One
/ Keys
The/ keys are used to scroll through the menus, menu items, and through the range
of item values that can be selected. Depending on the item type the values may be
numerical, specific properties (on / off), or a bar graph.
Emergency Key - Red with Black Letters
EMERGENCY Key
The red EMERGENCY key puts the controller into emergency mode. If the room is under
negative room pressure control, the emergency mode maximizes the negative pressure.
Conversely, if the room is under positive room pressure control, the emergency mode
maximizes the positive pressure.
Pressing the EMERGENCY key causes the display to flash ”EMERGENCY”, the red
alarm light to flash on and off, and the audible alarm to beep intermittently. To return to
control mode press the EMERGENCY or RESET key.
Alarms
SureFlow controller has visual (red light) and audible alarms to inform you of changing conditions.
The alarm levels (setpoints) are determined by administrative personnel, Industrial Hygienists, or
the facilities group depending on the organization.
The alarms, audible and visual, activate whenever the preset alarm level is reached. Depending
on the SureFlow controller items installed, programmed alarms activate when room pressure is
low or inadequate, when room pressure is high or too great, or when the supply or general
exhaust air flow is insufficient. When the laboratory is operating safely, no alarms sound.
Example: The low alarm is programmed to activate when the room pressure reaches –0.001
inches H2O. When the room pressure drops below –0.001 inches H2O (gets closer to
zero), the audible and visual alarms activate. The alarms turn off (when set to
unlatched) when the unit returns to the safe range which is defined as negative
pressure greater than –0.001 inches H2O.
Visual Alarm Operation
The red light on the front of the unit indicates an alarm condition. The red light is on for all alarm
conditions, low alarms, high alarms, and emergency. The light is on continuously in a low or high
alarm condition, and flashes in an emergency condition.
Audible Alarm Operation- EMERGENCY key
When the EMERGENCY key is pressed, the audible alarm beeps intermittently until the
EMERGENCY or RESET key is pressed terminating the emergency alarm. The emergency alarm
cannot be silenced by pressing the MUTE key.
User Basics
5
Audible Alarms - All Except Emergency
The audible alarm is continuously on in all low and high alarm conditions. The audible alarm can
be temporarily silenced by pressing the MUTE key. The alarm is silent for a period of time (see
MUTE TIMEOUT to program time period). When the time out period ends, the audible alarm
turns back on if the alarm condition is still present.
You can program the audible alarm to be permanently turned off (see AUDIBLE ALM). The red
alarm light still turns on in alarm conditions when audible alarm is turned off. The audible and
visual alarms can be programmed to either automatically turn off when the unit returns to the safe
range or to stay in alarm until the RESET key is pressed (See ALARM RESET).
6
Part One
Before Calling TSI
This manual should answer most questions and resolve most problems you may encounter. If
you need assistance or further explanation, contact your local TSI representative or TSI. TSI is
committed to providing high quality products backed by outstanding service.
Please have the following information available prior to contacting your authorized TSI
Manufacturer's Representative or TSI:
- Model number of unit*
8681- ____
- Software revision level*
- Facility where unit is installed
* First two items that scroll when TEST key is pressed
Due to the different SureFlow models available, the above information is needed to accurately
answer your questions.
For the name of your local TSI representative or to talk to TSI service personnel, please call TSI
at:
U.S. AND CANADA
Sales & Customer Service:
(800) 874-2811/(651) 490-2811
Fax:
(651) 490-3824
SHIP/MAIL TO:
TSI Incorporated
ATTN: Customer Service
500 Cardigan Road
Shoreview, MN 55126
USA
User Basics
OTHER COUNTRIES
Sales & Customer Service:
(001 651) 490-2811
Fax:
(001 651) 490-3824
E-MAIL
[email protected]
WEB SITE
www.tsi.com
7
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8
Part One
PART TWO
Technical Section
The AOC is ready to use after being properly installed. Please note that the AOC is part of the
DIM module and is not a separate component. Where AOC is written, the overall control
sequence is being discussed. When DIM is written, the manual is referring to programming the
unit or viewing what is on the display. The pressure sensor is factory calibrated prior to shipping
and should not need adjustment. The flow stations need a zero point and/or a span programmed
prior to using them. The Digital Interface Module (DIM) is programmed with a default
configuration that can be easily modified to fit your application.
The Technical section is separated into five parts that cover all aspects of the unit. Each section
is written as independently as possible to minimize flipping back and forth through the manual for
an answer.
The Software Programming section explains the programming keys on the DIM. In addition, the
programming sequence is described, which is the same regardless of the menu item being
changed. At the end of this section is an example of how to program the DIM.
The Menu and Menu Item section lists all of the software items available to program and change.
The items are grouped by menu which means all setpoints are in one menu, alarm items in
another, etc. The menu items and all related information are listed in table format and include
menu item name, description of menu item, range of programmable values, and how the unit
shipped from the factory (default values).
The Setup / Checkout section; explains the AOC controller theory of operation, lists the menu
items that need to be programmed for the system to operate, provides a programming example,
and provides information to confirm system is operating correctly.
The Calibration section describes the required technique to compare the pressure sensor reading
to a thermal anemometer, and how to adjust the zero and span to obtain an accurate calibration.
This section also describes how to zero a TSI flow station transducer.
The Maintenance and Repair Parts section covers all routine maintenance of equipment, along
with a list of repair parts.
Software Programming
Programming the SureFlow controller is quick and easy if the programming keys are understood
and the proper key stroke procedure is followed. The programming keys are defined first,
followed by the required keystroke procedure. At the end of this section is a programming
example.
NOTE: The unit is always operating while programming unit (except when checking the control
outputs). When a menu item value is changed, the new value takes effect immediately
after saving the change.
Technical Section
9
NOTE: This section covers programming the instrument through the keypad and display. If
programming through RS-485 communications, use the host computer’s procedure. The
changes take place immediately upon “saving data.”
Programming Keys
The four keys with blue characters (refer to Figure 4) are used to program or configure the unit to
fit your particular application. Programming the instrument changes how the unit functions, so
thoroughly review the items to be changed.
Figure 4. Programming Keys
MENU Key
The MENU key has three functions.
1.
The MENU key is used to gain access to the menus when the unit is in the
normal operating mode. Pressing the key once exits the normal operating mode
and enters the programming mode. When the MENU key is first pressed, the
first two menus are listed.
2.
When the unit is being programmed, the MENU key acts like an escape key.
- When scrolling through the main menu, pressing the MENU key returns the
unit to standard operating mode.
- When scrolling through the items on a menu, pressing the MENU key
returns you to the list of menus.
- When changing data in a menu item, pressing the MENU key escapes out of
the item without saving changes.
3.
When programming is complete, pressing the MENU key returns the unit to
normal operating mode.
SELECT Key
The SELECT key has three functions.
10
1.
The SELECT key is used to gain access to specific menus. To access a menu,
scroll through the menus (using arrow keys) and place the flashing cursor on
the desired menu. Press the SELECT key to select the menu. The first line on
the display will now be the selected menu and the second line shows the first
menu item.
2.
The SELECT key is used to gain access to specific menu items. To access a
menu item scroll through the menu items until item appears. Press the SELECT
key and the menu item now appears on the first line of the display and the
second line shows the item value.
3.
Pressing the SELECT key when finished changing an item saves the data and
exits back to the menu items. An audible tone (3 beeps) and visual display
(“saving data”) gives confirmation data is being saved.
Part Two
/ Keys
The / keys are used to scroll through the menus, menu items, and through the range
of item values that can be selected. Depending on the menu item selected the value may
be numerical, specific property (on / off), or a bar graph.
NOTE: When programming a menu item, continuously pressing the arrow key scrolls
through the values faster than if arrow key is pressed and released.
Keystroke Procedure
The keystroke operation is consistent for all menus. The sequence of keystrokes is the same
regardless of the menu item being changed.
1. Press the MENU key to access the main menu.
2. Use the / keys to scroll through the menu choices. The blinking cursor needs to be on
the first letter of the menu you want to access.
3. Press the SELECT key to access chosen menu.
4. The menu selected is now displayed on line one and the first menu item is displayed on line
2. Use the / keys to scroll through the menu items. Scroll through the menu items until
desired item is displayed.
NOTE: If “Enter Code” is flashing, the access code must be entered before you can enter the
menu. Access code is found in Appendix C. Appendix C may have been removed
from the manual for security reasons.
5. Press the SELECT key to access chosen item. The top line of display shows menu item
selected, while the second line shows current item value.
6. Use the / keys to change item value.
7. Save the new value by pressing the SELECT key (pressing the MENU key exits out of menu
function without saving data).
8. Press the MENU key to exit current menu, and return to main menu.
9. Press the MENU key again to return to normal instrument operation.
If more than one item is to be changed, skip steps 8 and 9 until all changes are complete. If more
items in the same menu are to be changed, scroll to them after saving the data (step 7). If other
menus need to be accessed, press the MENU key once to access list of menus. The instrument
is now at step 2 of the keystroke sequence.
Technical Section
11
Programming Example
The following example demonstrates the keystroke sequence explained above. In this example
the high alarm setpoint is changed from -0.002 inches H2O to -0.003 inches H2O.

Unit is in normal operation scrolling room pressure, flows, etc...
Pressure is shown in this case.

Press the MENU key to gain access to the menus.
The first two (2) menu choices are displayed.

PRESSURE
-.00100 “H2O
SETPOINTS
ALARM
Press the  key once. Blinking cursor should be on A of Alarm.
Press the SELECT key to access the ALARM menu.
NOTE: Blinking cursor must be on A in Alarm.
Line 1 shows menu selected.
Line 2 shows first menu item.

Press the  key once. HIGH ALARM is shown on display.
Menu selected
Item name


ALARM
HIGH ALARM
Press the SELECT key to access the high alarm setpoint. The item
name (HIGH ALARM) is displayed on line 1, and the item's current
value is displayed on line 2.
Item Name
Current Value

ALARM
LOW ALARM
Press the  key to change the high alarm setpoint to - 0.003
inches H2O.
HIGH ALARM
-.00200 "H2O

HIGH ALARM
- .00300 "H2O
12
Part Two

Press the SELECT key to save the new negative high alarm
setpoint.
Three short beeps sound indicating that the data is
being saved.
HIGH ALARM
Saving Data
Immediately after the data is saved, the SureFlow
controller returns to the menu level displaying the
menu title on the top line of the display and the menu
item on the bottom line (goes to step 4).
ALARM
HIGH ALARM
WARNING: If the MENU key was pressed instead of the SELECT key, the new data
would not have been saved, and the SureFlow controller would have
escaped back to the menu level shown in step 3.

Press the MENU key once to return to the menu level:
ALARM
CONFIGURE

Press the MENU key a second time to return to the normal
operating level:
Unit is now back in normal
operation
Technical Section
PRESSURE
-.00100 "H2O
13
Menu and Menu Items
The SureFlow controller is a very versatile device which can be configured to meet your specific
application. This section describes all of the menu items available to program and change.
Changing any item is accomplished by using the keypad, or if communications are installed
through the RS-485 Communications port. If you are unfamiliar with the keystroke procedure,
please see Software Programming for a detailed explanation. This section provides the following
information:

Complete list of menu and all menu items.

Gives the menu or programming name.

Defines each menu item’s function; what it does, how it does it, etc.

Gives the range of values that can be programmed.

Gives default item value (how it shipped from factory).
The menus covered in this section are divided into groups of related items to ease programming.
As an example all setpoints are in one menu, alarm information in another, etc. The manual
follows the menus as programmed in the controller. The menu items are always grouped by
menu and then listed in menu item order, not alphabetical order. Figure 5 shows a chart of all the
Model 8681 controller menu items.
14
Part Two
SETPOINTS
ALARM
CONFIGURE
CALIBRATION
SETPOINT
VENT MIN SET
COOLING FLOW
UNOCCUPY SET
MAX SUP SET
MIN EXH SET
TEMP SETP
UNOCC TEMP
MIN OFFSET
MAX OFFSET
LOW ALARM
HIGH ALARM
MIN SUP ALM
MAX EXH ALM
ALARM RESET
AUDIBLE ALM
ALARM DELAY
ALARM RELAY
MUTE TIMEOUT
UNITS
EXH CONFIG
NET ADDRESS*
MAC ADDRESS*
ACCESS CODES
TEMP CAL
SENSOR SPAN
ELEVATION
CONTROL
SYSTEM FLOW
FLOW CHECK
DIAGNOSTICS
SPEED
SENSITIVITY
SUP CONT DIR
EXH CONT DIR
Kc VALUE
Ti VALUE
Kc OFFSET
REHEAT SIG
TEMP DIR
TEMP DB
TEMP TR
TEMP TI
TOT SUP FLOW
TOT EXH FLOW
OFFSET VALUE
SUP SETPOINT
EXH SETPOINT
SUP FLOW IN
EXH FLOW IN
HD1 FLOW IN
HD2 FLOW IN**
CONTROL SUP
CONTROL EXH
CONTROL TEMP
SENSOR INPUT
SENSOR STAT
TEMP INPUT
ALARM RELAY
RESET TO DEF
SUPPLY FLOW
EXHAUST FLOW
HOOD FLOW
SUP DCT AREA
SUP FLO ZERO
SUP LO SETP
SUP HI SETP
SUP LOW CAL
SUP HIGH CAL
FLO STA TYPE
TOP VELOCITY
RESET CAL
EXH DCT AREA
EXH FLO ZERO
EXH LO SETP
EXH HI SETP
EXH LOW CAL
EXH HIGH CAL
FLO STA TYPE
TOP VELOCITY
RESET CAL
HD1 DCT AREA
HD2 DCT AREA**
HD1 FLO ZERO
HD2 FLO ZERO**
MIN HD1 FLOW
MIN HD2 FLOW**
HD1 LOW CAL
HD1 HIGH CAL
HD2 LOW CAL**
HD2 HIGH CAL **
FLO STA TYPE
TOP VELOCITY
RESET CAL
*MAC ADDRESS Menu Item only appears as a menu option for a Model 8681-BAC Adaptive
Offset Controller which includes a BACnet® MSTP board. The Menu Item NET ADDRESS is
deleted as a menu option on the Model 8681-BAC.
**These menu items do not appear as options on the Model 8681-BAC.
Figure 5: Menu Items - Model 8681/8681-BAC Controller
Technical Section
15
16
SETPOINTS MENU
MENU ITEM
PRESSURE
SETPOINT
SOFTWARE
NAME
SETPOINT
ITEM DESCRIPTION
The SETPOINT item sets the pressure control setpoint.
The SureFlow controller maintains this setpoint, negative
or positive, under normal operating conditions.
ITEM RANGE
0 to -0.19500 “H2O
or
0 to +0.19500 H2O
DEFAULT
VALUE
-0.00100” H2O
Pressure differential is not maintained by direct pressure
control; i.e. modulating dampers in response to pressure
changes. The pressure signal is an AOC input that is
used to calculate the required air flow offset value. The
calculated offset value changes the supply (or exhaust)
flow volume which changes the pressure differential.
When the calculated offset value is between the MIN
OFFSET and MAX OFFSET, room pressure control can
be maintained. If the offset required to maintain pressure
is less than the MIN OFFSET or greater the MAX
OFFSET, pressure control will not be maintained.
VENTILATION
MINIMUM
SUPPLY FLOW
SETPOINT
VENT MIN
SET
The VENT MIN SET item sets the ventilation supply
airflow setpoint. This item provides a minimum supply
airflow to meet the ventilation requirement, by preventing
the supply flow from going below the preset minimum
flow.
The controller will not allow the supply air damper to be
closed further than the VENT MIN SET setpoint. If room
pressure is not maintained at minimum supply flow, the
general exhaust damper modulates open until pressure
setpoint is reached (provided offset is between MIN
OFFSET and MAX OFFSET).
0 to 30,000 CFM
(0 to 14100 l/s)
Linear based flow
stations 0 to TOP
VELOCITY times
the duct area in
square feet (ft2):
square meters (m2).
0
Part Two
Technical Section
SETPOINTS MENU (continued)
MENU ITEM
SPACE
COOLING
SUPPLY FLOW
SETPOINT
SOFTWARE
NAME
COOLING
FLOW
ITEM DESCRIPTION
The COOLING FLOW item sets the space cooling supply
airflow setpoint. This item defines a supply air flow
intended to meet the space’s cooling requirements by
allowing the supply flow to increase, gradually, to the
COOLING FLOW setpoint, from a minimum ventilation
rate, when the space temperature is too warm..
If room pressure is not maintained at minimum
temperature flow, the general exhaust damper modulates
open until pressure setpoint is reached (provided offset is
between MIN OFFSET and MAX OFFSET).
ITEM RANGE
0 to 30,000 CFM
(0 to 14100 l/s)
DEFAULT
VALUE
0
Linear based flow
stations 0 to TOP
VELOCITY times
the duct area in
square feet (ft2):
square meters (m2).
WIRING: This item requires 1000 platinum RTD to be
wired to the TEMPERATURE input (DIM pins
23 and 24). The temperature sensor toggles
the AOC between VENT MIN SET and
COOLING FLOW.
UNOCCUPIED
SUPPLY FLOW
MINIMUM
UNOCCUPY
SET
The UNOCCUPY SET item sets a minimum supply flow
setpoint when the laboratory is unoccupied (requires
fewer air changes per hour). When UNOCCUPY SET is
active, the VENT MIN SET and COOLING FLOW
setpoints are turned off, since only one minimum supply
setpoint can be enabled.
The controller will not allow the supply air damper to be
closed further than the UNOCCUPY SET setpoint. If
room pressure is not maintained at minimum supply flow,
the general exhaust damper modulates open until
pressure setpoint is reached (provided required offset is
between MIN OFFSET and MAX OFFSET).
17
WIRING: This item is enabled through RS 485
communication sends commands. When the
UNOCCUPY SET menu item is enabled, VENT
MIN SET and COOLING FLOW are disabled.
Disabling UNOCCUPY SET and enables VENT
MIN SET and COOLING FLOW.
0 to 30,000 CFM
(0 to 14100 l/s)
Linear based flow
stations 0 to TOP
VELOCITY times
the duct area in
square feet (ft2):
square meters (m2).
0
18
SETPOINTS MENU (continued)
MENU ITEM
MAXIMUM
SUPPLY FLOW
SETPOINT
SOFTWARE
NAME
MAX SUP
SET
ITEM DESCRIPTION
The MAX SUP SET item sets the maximum supply air
flow into the laboratory. The controller will not allow the
supply air damper to open further than the MAX SUP
SET flow setpoint.
NOTE: The laboratory may not hold pressure setpoint
when supply air is limited.
MINIMUM
EXHAUST
FLOW
SETPOINT
MIN EXH
SET
The MIN EXH SET item sets the minimum general
exhaust air flow out of the laboratory. The controller will
not allow the general exhaust air damper to close further
than the MIN EXH SET flow setpoint.
NOTE: This item requires a TSI compatible flow station
and control damper to be mounted in the general
exhaust duct.
SPACE
TEMPERATUR
E SETPOINT
TEMP SETP
The TEMP SETP item sets the temperature setpoint of
the space. The SureFlow controller maintains the
temperature setpoint under normal operating conditions.
WIRING: The 1000 platinum RTD temperature sensor
is connected to the temp input (pins 23 & 24,
DIM). The temperature sensor signal is
continuously monitored by the AOC.
ITEM RANGE
0 to 30,000 CFM
(0 to 14100 l/s)
DEFAULT
VALUE
OFF
Linear based flow
stations 0 to TOP
VELOCITY times
the duct area in
square feet (ft2):
square meters (m2).
0 to 30,000 CFM
(0 to 14100 l/s)
OFF
Linear based flow
stations 0 to TOP
VELOCITY times
the duct area in
square feet (ft2):
square meters (m2).
50F to 85F.
68F
Part Two
Technical Section
SETPOINTS MENU (continued)
MENU ITEM
UNOCCUPIED
SPACE
TEMPERATUR
E SETPOINT
SOFTWARE
NAME
UNOCC
TEMP
ITEM DESCRIPTION
The UNOCC TEMP item sets the temperature setpoint of
the space during unoccupied mode. The SureFlow
controller maintains the temperature setpoint under
unoccupied operating conditions.
ITEM RANGE
50F to 85F.
DEFAULT
VALUE
68F
WIRING: The 1000 platinum RTD temperature sensor
is connected to the temp input (pins 23 & 24,
DIM). The temperature sensor signal is
continuously monitored by the AOC.
MINIMUM
FLOW OFFSET
MIN OFFSET
The MIN OFFSET item sets the minimum air flow offset
between total exhaust flow (fume hood, general exhaust,
other exhaust) and total supply flow.
- 10,000 to 10,000
CFM
0
MAXIMUM
FLOW OFFSET
MAX
OFFSET
The MAX OFFSET item sets the maximum air flow offset
between total exhaust flow (fume hood, general exhaust,
other exhaust) and total supply flow.
- 10,000 to 10,000
CFM
0
END OF
MENU
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
19
20
ALARM MENU
MENU ITEM
LOW
PRESSURE
ALARM
SOFTWARE
NAME
LOW ALARM
ITEM RANGE
OFF
0 to -0.19500 "H2O
0 to +0.19500 "H2O
OFF
0 to -0.19500 "H2O
0 to +0.19500 "H2O
OFF
0 to 30,000 CFM
(0 to 14100 l/s)
OFF
HIGH
PRESSURE
ALARM
HIGH
ALARM
The HIGH ALARM item sets the high pressure alarm
setpoint. A high alarm condition is defined as when the
room pressure rises above the HIGH ALARM setpoint.
MINIMUM
SUPPLY FLOW
ALARM
MIN SUP
ALM
The MIN SUP ALM item sets the supply flow alarm
setpoint. A minimum flow alarm is defined as when the
supply duct flow is less than the MIN SUP ALM setpoint.
NOTE: Supply air duct size SUP DCT AREA (Supply
Flow menu) must be entered before MIN SUP
ALM can be accessed. Actual total supply air
flow is found in TOT SUP FLOW menu item
(system flow menu).
MAXIMUM
EXHAUST
FLOW ALARM
MAX EXH
ALM
DEFAULT
VALUE
OFF
ITEM DESCRIPTION
The LOW ALARM item sets the low pressure alarm
setpoint. A low alarm condition is defined as when the
room pressure falls below or goes in the opposite
direction of the LOW ALARM setpoint.
WIRING: This item is disabled when the UNOCCUPY
SET is enabled [AUX key is pressed, or the
RS 485 communications sends a command].
The MAX EXH ALM item sets the general exhaust duct’s
flow alarm setpoint. A maximum flow alarm is defined as
when the general exhaust duct flow is greater than the
MAX EXH ALM setpoint.
Part Two
NOTE: General exhaust air duct size EXH DCT AREA
(Exhaust Flow menu) must be entered before
MAX EXH ALM can be accessed. Actual total
exhaust air flow is found in TOT EXH FLOW
menu item (system flow menu).
Linear based flow
stations 0 to TOP
VELOCITY times
the supply duct area
in square feet (ft2 ):
square meters (m2 ).
0 to 30,000 CFM
(0 to 14100 l/s)
Linear based flow
stations 0 to TOP
VELOCITY times
the supply duct area
in square feet (ft2 ):
square meters (m2 ).
OFF
Technical Section
ALARM MENU (continued)
MENU ITEM
ALARM RESET
SOFTWARE
NAME
ALARM
RESET
AUDIBLE
ALARM
DEFAULT
VALUE
UNLATCHED
ITEM DESCRIPTION
The ALARM RESET item selects how the alarms
terminate after the unit returns to control setpoint
(pressure or flow). UNLATCHED (alarm follow)
automatically resets the alarms when the unit reaches
control setpoint. LATCHED requires the staff to press the
RESET key after the unit returns to control setpoint. The
ALARM RESET affects the audible alarm, visual alarm,
and relay output, which means all are latched or
unlatched.
ITEM RANGE
LATCHED
OR
UNLATCHED
AUDIBLE
ALM
The AUDIBLE ALM item selects whether the audible
alarm is turned ON or OFF. Selecting ON requires the
staff to press the MUTE key to silence the audible alarm.
Selecting OFF permanently mutes all audible alarms,
except when the EMERGENCY key is pressed.
ON or OFF
ON
ALARM DELAY
ALARM
DELAY
The ALARM DELAY determines the length of time the
alarm is delayed after an alarm condition has been
detected. This delay affects the visual alarm, audible
alarm, and relay outputs. An ALARM DELAY prevents
nuisance alarms from people entering and leaving the
laboratory.
20 to 600
SECONDS
20 SECONDS
ALARM RELAY
ALARM
RELAY
The ALARM RELAY item selects which alarms activate
the relay contacts (pins 13, 14). Selecting PRESSURE
triggers the relays when a pressure alarm is present.
Selecting FLOW triggers the relays when a low flow
condition exists. This item only affects the relay contacts,
all audible and visual alarms are still active regardless of
the ALARM RELAY status.
PRESSURE or
FLOW
PRESSURE
NOTE: Pins 13, 14 -Alarm relay contacts; configurable
for pressure or flow alarms.
21
22
ALARM MENU (continued)
MENU ITEM
MUTE
TIMEOUT
SOFTWARE
NAME
MUTE
TIMEOUT
ITEM DESCRIPTION
The MUTE TIMEOUT determines the length of time the
audible alarm is silenced after the MUTE key is pressed.
This delay temporarily mutes the audible alarm.
ITEM RANGE
5 to 30 MINUTES
DEFAULT
VALUE
5 MINUTES
NOTE: If the DIM is in alarm when MUTE TIMEOUT
expires, the audible alarm turns on. When the
pressure returns to the safe range, the MUTE
TIMEOUT is canceled. If the room goes back
into an alarm condition, the MUTE key must be
pressed again to mute the audible alarm.
END OF
MENU
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
ALARM CONSTRAINTS
There are a number of constraints built into the software that prevent users from programming conflicting alarm information. These are as
follows:
1. The AOC does not allow the pressure alarms to be programmed within 20 ft/min (0.00028 in. H2O at 0.001 in. H2O) of the control
setpoint.
Example: The control SETPOINT is set at -0.001 in. H2O. The LOW ALARM setpoint cannot be set higher than -0.00072 in. H2O.
Conversely, the HIGH ALARM setpoint cannot be set lower than -0.00128 in. H2O.
2. The minimum flow alarms: MIN SUP ALM, MIN EXH ALM must be programmed to be at least 50 CFM less than the minimum flow
setpoint.
Part Two
3. The pressure alarms: LOW ALARM, HIGH ALARM can be programmed for positive or negative pressure. However, both the low and
high alarm must be set either positive or negative. The AOC does not allow one positive alarm and one negative alarm.
4. Alarms do not terminate until the pressure or flow slightly exceeds alarm setpoint.
5. The ALARM RESET item selects how the alarms terminates when controller returns to the safe range. The pressure and flow alarms
all terminate the same; they are either latched or unlatched. If unlatched is selected, the alarms automatically turn off when the value
Technical Section
slightly exceeds setpoint. If latched is selected, the alarms will not terminate until the controller returns to setpoint and the RESET key
is pressed.
6. There is a programmable ALARM DELAY that determines how long to delay before activating the alarms. This delay affects all
pressure and flow alarms.
7. The MUTE TIMEOUT item sets the length of time the audible alarm is off for all pressure and flow alarms.
8. The display can only show one alarm message. Therefore, the controller has an alarm priority system, with the highest priority alarm
being displayed. If multiple alarms exist, the lower priority alarms will not display until after the highest priority alarm has been
eliminated. The alarm priority is as follows:
Pressure sensor - low alarm
Pressure sensor - high alarm
Low supply flow alarm
Low exhaust flow alarm
Data error
9. The low and high pressure alarms are absolute values. The chart below shows how the values must be programmed in order to
operate correctly.
-0.2 inches H2O
0
+0.2 inches H2O
(maximum negative)
High
Negative
Alarm
Negative
Setpoint
(maximum positive)
Low
Negative
Alarm
Zero
Low
Positive
Alarm
Positive
Setpoint
High
Positive
Alarm
The value of each setpoint or alarm is unimportant (except for small dead band) in graph above. It is important to understand that the
negative (positive) low alarm must be between zero (0) pressure and the negative (positive) setpoint, and that the high alarm is a greater
negative (positive) value than setpoint.
23
24
CONFIGURE MENU
MENU ITEM
DISPLAYED
UNITS
GENERAL
EXHAUST DUCT
CONFIGURATIO
N
SOFTWARE
NAME
UNITS
EXH
CONFIG
ITEM DESCRIPTION
The UNITS item selects the unit of measure that the DIM
displays all values (except calibration span). These units
display for all menu items setpoints, alarms, flows, etc.
ITEM RANGE
FT/MIN, m/s,
in. H2O, Pa
The EXH CONFIG menu item determines the exhaust
configuration. If the general exhaust duct is separate from
the total exhaust, select UNGANGED (left side of Figure
6). If the general exhaust duct is part of the total exhaust,
select GANGED (right side of Figure 6). The correct
configuration is required for the control algorithm to
function correctly.
GANGED or
UNGANGED
Figure 6: Exhaust Configuration
NOTE: The flow station input for a GANGED flow
measurement is to be wired to the applicable fume
hood flow input; either HD 1 INPUT (terminals 11 &
12) or the HD 2 INPUT (terminals 27 & 28).
NOTE: A GANGED flow measurement configuration still
requires a separate General Exhaust flow
measurement (right side of Figure 6).
DEFAULT
VALUE
“H2O
UNGANGED
Part Two
Technical Section
CONFIGURE MENU (continued)
MENU ITEM
NETWORK
ADDRESS**
SOFTWARE
NAME
NET
ADDRESS
ITEM DESCRIPTION
The NET ADDRESS item is used to select the main
network address of the individual room pressure device.
Each unit on the network must have its own unique
address. The values range from 1-247. If RS-485
communications are being used, a unique NET
ADDRESS must be entered into the unit.
ITEM RANGE
1 to 247
DEFAULT
VALUE
1
1 to 127
1
ON or OFF
OFF
There is no priority between the RS-485 and keypad. The
most recent signal by either RS-485 or keypad initiates a
change.
RS-485 communications allows you access to all menu
items except calibration and control items. The RS-485
network can initiate a change at any time.
NOTE: The Model 8681 network protocol is Modbus.
MAC Address**
MAC
ADDRESS
MENU ACCESS
CODES
ACCESS
CODES
END OF
MENU
The MAC ADDRESS assigns the device an address on
the MS/TP BACnet® network. This address must be
unique for each device on the BACnet® network.
The ACCESS CODES item selects whether an access
code (pass code) is required to enter the menu. The
ACCESS CODES item prevents unauthorized access to
a menu. If the ACCESS CODES is ON, a code is
required before the menu can be entered. Conversely, if
the ACCESS CODES is OFF, no code is required to
enter the menu.
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
25
**The MAC ADDRESS Menu Item replaces the Network Address Menu Item on SureFlow controllers provided with the BACnet® MSTP
board.
26
CALIBRATION MENU
MENU ITEM
TEMPERATURE
CALIBRATION
SENSOR SPAN
SOFTWARE
NAME
TEMP CAL
SENSOR
SPAN
ITEM DESCRIPTION
The TEMP CAL is used to enter the actual space
temperature. This adjustment offsets the temperature
sensor curve.
The SENSOR SPAN item is used to match or calibrate
the TSI pressure sensor (velocity sensors) to the average
room pressure velocity as measured by a portable air
velocity meter.
ITEM RANGE
50°F to 85°F
DEFAULT
VALUE
NONE
0
0 to 10,000 feet
above sea level
0
NOTE: The pressure sensor is factory calibrated. No
initial adjustment should be necessary.
ALTITUDE
ELEVATION
The ELEVATION item is used to enter the elevation of
the building above sea level. This item has a range of 0
to 10,000 feet in 1,000 foot increments. The pressure
value needs to be corrected due to changes in air density
at different elevations.
END OF
MENU
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
Part Two
Technical Section
CONTROL MENU
MENU ITEM
SPEED
SOFTWARE
NAME
SPEED
SENSITIVITY
SENSITIVITY
ITEM DESCRIPTION
The SPEED item is used to select the control output speed
(supply and general exhaust). When this item is selected, a
bar graph is shown on the display. There are 10 bars, each
one representing 10% of speed. Starting from the right side
(+ sign), 10 bars displayed indicates maximum speed. This
is the fastest the controller will operate. 1 bar is the slowest
the controller will operate. The more bars displayed, the
faster the control output.
ITEM RANGE
1 to 10 bars
DEFAULT
VALUE
5 bars
The SENSITIVITY item is used to select the integral dead
band. The integral dead band determines when the
controller uses integral control (slow control), and when the
controller enters PID control (fast control). When this item is
selected, a bar graph is shown on the display.
0 to 10 bars
5 bars
There are 10 bars total, with each one representing 50
CFM. Starting from the right side (+ sign), 10 bars displayed
indicates no dead band so the controller is always in PID
control mode. Each bar missing represents ±50 CFM of
integral dead band. The less bars displayed, the larger the
integral dead band. For example, with 8 bars displayed (2
bars missing) and an offset of 500 CFM, the integral dead
band is between 400 and 600 CFM. When the measured
offset is within this range, integral or slow control is used.
However, when the flow offset falls below 400 CFM or rises
above 600 CFM, PID control is enabled until the unit
returns within the dead band.
The SENSITIVITY item has a unique feature that when
zero bars are displayed, the unit never goes into PID
control. The control output is always a slow control signal.
27
WARNING: When SENSITIVITY is set for 10 bars, the
system is always in PID control, which will
probably cause an unstable system. It is
recommended that SENSITIVITY be set at 9
bars or less.
28
CONTROL MENU (continued)
MENU ITEM
SUPPLY
DAMPER
CONTROL
SIGNAL
DIRECTION
SOFTWARE
NAME
SUP CONT
DIR
ITEM DESCRIPTION
The SUP CONT DIR item determines the control signal’s
output direction. As an example, if the control system
closes the supply damper instead of opening the damper,
this option reverses the control signal to now open the
damper.
ITEM RANGE
DIRECT or
REVERSE
DEFAULT
VALUE
DIRECT
EXHAUST
DAMPER
CONTROL
SIGNAL
DIRECTION
EXH CONT
DIR
The EXH CONT DIR item determines the control signal’s
output direction. As an example, if the control system
closes the exhaust damper instead of opening the
damper, this option reverses the control signal to now
open the damper.
DIRECT or
REVERSE
DIRECT
FLOW
TRACKING
CONTROL Kc
VALUE &
Ti VALUE
Kc VALUE
Ti VALUE
WARNING: The Kc VALUE and Ti VALUE allow you to
manually change the primary PID control
loop variables. DO NOT CHANGE THESE
VALUES UNLESS YOU HAVE A
THOROUGH UNDERSTANDING OF PID
CONTROL LOOPS. CONTACT TSI FOR
ASSISTANCE PRIOR TO CHANGING
ANY VALUES. Contact TSI for assistance
in determining your control problem and for
instructions on how to change a value.
Incorrectly changing a value results in poor
or nonexistent control.
Kc = 0 to 1000
Ti = 0 to 1000
Kc = 80
Ti = 200
Suggestion: Before changing Kc or Ti, change the
SPEED or adjust the SENSITIVITY to try to
eliminate the problem.
Part Two
The Kc VALUE item changes the gain control coefficient
of the primary control loop (flow tracking loop). When this
item is entered, a value for Kc is indicated on the display.
If the AOC is not controlling correctly, the Kc gain control
coefficient may need adjusting. Decreasing Kc slows the
control system down, which increases stability.
Increasing Kc will increase the control system which may
cause system instability.
The range of values
is very large. Poor
control occurs if
values are more
than twice or less
than 1/2 the default
value.
Technical Section
CONTROL MENU (continued)
MENU ITEM
FLOW
TRACKING
CONTROL Kc
VALUE &
Ti VALUE
(continued)
ADAPTIVE
OFFSET
CONTROL Kc
VALUE
SOFTWARE
NAME
Kc VALUE
Ti VALUE
Kc OFFSET
ITEM DESCRIPTION
The Ti VALUE item changes the integral control
coefficient of the primary control loop (flow tracking loop).
When this item is entered, a value for Ti is indicated on
the display. If the AOC is not controlling correctly, the unit
may have an inappropriate integral control coefficient.
Increasing Ti slows the control system which increases
stability. Decreasing Ti increases the control system
speed which may cause system instability.
ITEM RANGE
DEFAULT
VALUE
WARNING: The Kc OFFSET sets the pressure control
PID variable. DO NOT CHANGE THIS
VALUE UNLESS YOU HAVE A
THOROUGH UNDERSTANDING OF PID
CONTROL LOOPS. CONTACT TSI FOR
ASSISTANCE PRIOR TO CHANGING
ANY VALUES. Contact TSI for assistance
in determining your control problem and for
instructions on how to change a value.
Incorrectly changing a value results in poor
or nonexistent control.
Kc = 0 to 1000
Kc = 200
The range of values
is very large. Poor
control occurs if
values are more
than twice or less
than 1/2 the default
value.
The Kc OFFSET item changes the gain control
coefficient of the secondary control loop (pressure control
loop). The pressure control loop is very slow when
compared to the primary flow control loop. This menu
item should not be changed unless problems with the
pressure control loop can be established (confirm
problem is not with primary flow control loop).
When this item is entered, a value for Kc is indicated on
the display. Decreasing Kc slows the pressure control
loop down, while increasing Kc increases the pressure
control loop speed.
29
TEMPERATUR
E OUTPUT
SIGNAL
REHEAT SIG
The REHEAT SIG item switches the supply and exhaust
control outputs from 0 to 10 VDC to 4 to 20 mA.
0 to 10 VDC or
4 to 20 mA
0 to 10 VDC
30
CONTROL MENU (continued)
MENU ITEM
TEMPERATUR
E CONTROL
DIRECTION
TEMPERATUR
E SETPOINT
DEAD BAND
SOFTWARE
NAME
TEMP DIR
TEMP DB
ITEM DESCRIPTION
The TEMP DIR item determines the control signal’s
output direction. As an example: If the control system
closes the reheat valve instead of opening this valve, this
option reverses the control signal to now open the valve.
ITEM RANGE
DIRECT OR
REVERSE
The TEMP DB item determines the controller’s
temperature control deadband, which is defined as the
temperature range above and below the temperature
setpoint (TEMP SETP or UNOCC TEMP), where the
controller will not take corrective action.
0.0F to 1.0F
If TEMP DB is set to 1.0°F, and the TEMP SETP is set to
70.0F, the controller will not take corrective action
unless the space temperature is below 69.0°F or above
71.0°F.
DEFAULT
VALUE
DIRECT
0.1F
Part Two
Technical Section
CONTROL MENU (continued)
MENU ITEM
TEMPERATUR
E SETPOINT
THROTTLING
RANGE
SOFTWARE
NAME
TEMP TR
ITEM DESCRIPTION
The TEMP TR item determines the controller’s
temperature control throttling range, which is defined as
the temperature range for the controller to fully open and
fully close the reheat valve.
If TEMP TR is set to 3.0F, and the TEMP SETP is set
to 70.0F, the reheat valve will be fully open when the
space temperature is 67F. Similarly, the reheat valve will
be fully closed when the space temperature is 73.0F.
ITEM RANGE
2.0°F to 20.0°F
DEFAULT
VALUE
3.0°F
31
32
CONTROL MENU (continued)
MENU ITEM
TEMPERATUR
E SETPONT
INTEGRAL
VALUE
SOFTWARE
NAME
TEMP TI
ITEM DESCRIPTION
WARNING: The TEMP TI item provides you with the
ability to manually change the temperature
control PI integral control loop variable. DO
NOT CHANGE THIS VALUE UNLESS
YOU HAVE A THOROUGH
UNDERSTANDING OF PI CONTROL
LOOPS. CONTACT TSI FOR
ASSISTANCE PRIOR TO CHANGING
ANY VALUES. Contact TSI for assistance
in determining your control problem and for
instructions on how to change a value.
Incorrectly changing a value results in poor
or nonexistent control.
Suggestion: Before changing TEMP TI adjust the
TEMP DB or adjust the TEMP TR to try to eliminate the
problem.
The TEMP TI item is used to read and change the
integral control coefficient. When this item is entered, a
value for TEMP TI is indicated on the display. If the
SureFlow controller is not controlling correctly, the unit
may have an inappropriate integral control coefficient.
Increasing TEMP TI slows the control system which
increases stability. Decreasing TEMP TI speeds up the
control system which may cause system instability.
END OF
MENU
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
ITEM RANGE
1 to 10000 sec
DEFAULT
VALUE
2400 sec
Part Two
Technical Section
SYSTEM FLOW MENU
MENU ITEM
TOTAL SUPPLY
AIR FLOW
SOFTWARE
NAME
TOT SUP
FLOW
ITEM DESCRIPTION
The TOT SUP FLOW menu item displays the current
total measured supply flow into the laboratory. This is a
system information only menu item: no programming is
possible.
ITEM RANGE
NONE: Read only
value
DEFAULT
VALUE
NONE
TOTAL
EXHAUST AIR
FLOW
TOT EXH
FLOW
The TOT EXH FLOW menu item displays the current
total measured exhaust flow out of the laboratory. This
item calculates total exhaust by summing EXH FLOW IN
and HD1 FLOW IN and HD2 FLOW IN. This is a system
information only menu item: no programming is possible.
NONE: Read only
value
NONE
CONTROL
OFFSET VALUE
OFFSET
VALUE
The OFFSET VALUE menu item displays the actual flow
offset being used to control the laboratory. The OFFSET
VALUE is calculated by the AOC control algorithm, which
uses the MIN OFFSET, MAX OFFSET, and SETPOINT
items to calculate required offset. This is a system
information only menu item: no programming is possible.
NONE: Read only
value
NONE
SUPPLY FLOW
SETPOINT
(CALCULATED)
SUP
SETPOINT
The SUP SETPOINT menu item displays the supply flow
setpoint, which is calculated by the AOC control
algorithm. The calculated SUP SETPOINT is a diagnostic
item used to compare the actual TOT SUP FLOW to the
calculated flow (they should match within 10%). This is a
system information only menu item: no programming is
possible.
NONE: Read only
value
NONE
33
34
SYSTEM FLOW MENU (continued)
MENU ITEM
GENERAL
EXHAUST
FLOW
SETPOINT
(CALCULATED)
SOFTWARE
NAME
EXH
SETPOINT
END OF
MENU
ITEM DESCRIPTION
The EXH SETPOINT menu item displays the general
exhaust flow setpoint, which is calculated by the AOC
control algorithm. The calculated EXH SETPOINT is a
diagnostic item used to compare the actual EXH FLOW
IN (from FLOW CHECK MENU) to the calculated flow.
This is a system information only menu item: no
programming is possible.
ITEM RANGE
NONE: Read only
value
DEFAULT
VALUE
NONE
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
FLOW CHECK MENU
MENU ITEM
SUPPLY AIR
FLOW
SOFTWARE
NAME
SUP FLOW
IN
ITEM DESCRIPTION
The SUP FLOW IN menu item displays the current
supply air flow. This item is a diagnostics tool used to
compare the supply flow to a traverse of the duct work. If
flow error is greater than 10%, calibrate flow station.
When a volt meter is hooked to the flow station output, a
voltage should be displayed. The exact voltage displayed
is relatively unimportant. It is more important that the
voltage is changing which indicates the flow station is
working correctly.
ITEM RANGE
NONE: Read only
value
DEFAULT
VALUE
NONE
Part Two
Technical Section
FLOW CHECK MENU
MENU ITEM
GENERAL
EXHAUST
FLOW
SOFTWARE
NAME
EXH FLOW
IN
ITEM DESCRIPTION
The EXH FLOW IN menu item displays the current exhaust
flow from a general exhaust. This item is a diagnostics tool
used to compare the general exhaust flow to a traverse of
the duct work. If flow error is greater than 10%, calibrate
flow station.
ITEM RANGE
NONE: Read only
value
DEFAULT
VALUE
NONE
When a volt meter is hooked to the flow station output, a
voltage should be displayed. The exact voltage displayed
is relatively unimportant. It is more important that the
voltage is changing which indicates the flow station is
working correctly.
FUME HOOD
EXHAUST
FLOW
HD1 FLOW
IN
HD2 FLOW
IN*
The HD# FLOW IN menu item displays the current
exhaust flow from a fume hood. This item is a diagnostics
tool to compare the hood flow reading to a traverse of the
duct work. If flow reading and traverse match within 10%,
no change is needed. If flow error is greater than 10%,
calibrate flow station.
When a volt meter is hooked to the flow station output, a
voltage should be displayed. The exact voltage displayed
is relatively unimportant. It is more important that the
voltage is changing which indicates the flow station is
working correctly.
END OF
MENU
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
*These menu items do not appear on SureFlow controllers with BACnet® communications.
NONE: Read only
value
NONE
35
36
DIAGNOSTICS MENU
MENU ITEM
SUPPLY AIR
CONTROL
OUTPUT
SOFTWARE
NAME
CONTROL
SUP
ITEM DESCRIPTION
The CONTROL SUP item manually changes the control output signal to the supply air
actuator/damper (or motor speed drive). When this item is entered, a number between 0 and 100% is
shown on the display indicating the control output value. Pressing the / keys change the count on
the display. Pressing the  key increases the displayed value, while pressing the  key decreases
the displayed value. The supply air damper or VAV box should change (modulate) as the number
changes. A count of 50% should position the damper approximately 1/2 open. On units controlling
variable frequency drives, fan speed should increase or decrease as numbers change.
WARNING: The CONTROL SUP function overrides the AOC control signal. Adequate room pressure
will NOT be maintained while in this item.
EXHAUST AIR
CONTROL
OUTPUT
CONTROL
EXH
The CONTROL EXH item manually changes the control output signal to the exhaust air
actuator/damper (or motor speed drive). When this item is entered, a number between 0 and 100% is
shown on the display indicating the control output value. Pressing the / keys changes the count
on the display. Pressing the  key increases the displayed value, while pressing the  key
decreases the displayed value. The exhaust air damper or VAV box should change (modulate) as the
number changes. A count of 50% should position the damper approximately 1/2 open. On units
controlling variable frequency drives, fan speed should increase or decrease as numbers change.
WARNING: The CONTROL EXH function overrides the AOC control signal. Adequate room pressure
will NOT be maintained while in this item.
REHEAT VAVLE
CONTROL
OUTPUT
CONTROL
TEMP
The CONTROL TEMP item manually changes the control output signal to the reheat valve. When this
item is entered, a number between 0 and 100% is shown on the display indicating the control output
value. Pressing the / keys changes the count on the display. Pressing the  key increases the
displayed value, while pressing the  key decreases the displayed value. The reheat control valve
should modulate as the number changes. A count of 50% should position the valve approximately 1/2
open.
WARNING: The CONTROL TEMP function overrides the AOC control signal. Adequate space
temperature will NOT be maintained while in this item.
Part Two
Technical Section
DIAGNOSTICS MENU (continued)
MENU ITEM
PRESSURE
SENSOR
SIGNAL CHECK
PRESSURE
SENSOR
SOFTWARE
NAME
SENSOR
INPUT
ITEM DESCRIPTION
The SENSOR INPUT item verifies that the DIM is receiving a signal from the pressure sensor. When
this item is entered, a voltage is indicated on the display. The exact voltage displayed is relatively
unimportant. It is more important that the voltage is changing which indicates the sensor is working
correctly.
0 volts represents a negative pressure of -0.2 inches H2O.
5 volts represents 0 pressure
10 volts represents a positive pressure of +0.2 inches H2O.
SENSOR
STAT
The SENSOR STAT item verifies that the RS-485 communications between the pressure sensor and
DIM is working correctly. Pressure sensor error messages do not display on DIM except when
SENSOR STAT item is selected. This item displays NORMAL if communications are established
correctly. If problems exist, one of four error messages display:
COMM ERROR - DIM cannot communicate with sensor. Check all wiring and pressure sensor
address.
Address must be 1.
SENS ERROR - Problem with sensor bridge. Physical damage to pressure sensor or sensor
circuitry. Unit is not field repairable. Send to TSI for repair.
CAL ERROR - Calibration data lost. Sensor must be returned to TSI to be calibrated.
DATA ERROR - Problem with EEPROM, field calibration, or analog output calibration lost. Check all
data programmed and confirm unit is function correctly.
TEMPERATURE
INPUT
TEMP INPUT
The TEMP INPUT item reads the input from the temperature sensor. When this item is entered, a
temperature is indicated on the display. The exact temperature displayed is relatively unimportant. It
is more important that the temperature changes indicating the temperature sensor is working
correctly. The output range that can be read is resistance.
RELAY OUTPUT
ALARM
RELAY
The relay menu items are used to change the state of the relay contact. When entered, the display
indicates either OPEN or CLOSED. The / keys are used to toggle the state of the relay.
Pressing the  key will OPEN the alarm contact. Pressing the  key will CLOSE the alarm contact.
When the contact is closed, the relay is in an alarm condition.
COMMUNICATION
CHECK
37
38
DIAGNOSTICS MENU (continued)
MENU ITEM
RESET THE
CONTROLLER
TO FACTORY
DEFAULT
SETTINGS
SOFTWARE
NAME
RESET TO
DEF
ITEM DESCRIPTION
When this menu item is entered, the 8681 prompts you to verify that you want to do this by indicating
NO. Use the  keys change the display to YES then press the SELECT key to reset the controller to
its factory defaults. Pressing the MENU key before the SELECT key exits out of the menu item.
WARNING: If YES is selected, the Model 8681 resets all menu items to their factory default settings:
The controller will have to be reprogrammed and recalibrated after this operation is
completed.
END OF
MENU
The END OF MENU item informs you that the end of a menu has been reached. You can either scroll
back up the menu to make changes, or press the SELECT or MENU key to exit out of the menu.
Part Two
Technical Section
SUPPLY FLOW MENU
MENU ITEM
SUPPLY AIR
DUCT SIZE
SOFTWARE
NAME
SUP DCT
AREA
ITEM DESCRIPTION
The SUP DCT AREA item inputs the supply air exhaust
duct size. The duct size is needed to compute the supply
air flow into the laboratory. This item requires a flow
station to be mounted in each supply duct.
If the DIM displays English units, area must be entered in
square feet. If metric units are displayed area must be
entered in square meters.
SUPPLY FLOW
STATION ZERO
SUP FLO
ZERO
The SUP FLO ZERO item establishes the flow station
zero flow point. A zero or no flow point needs to be
established in order to obtain a correct flow
measurement output (see Calibration section).
ITEM RANGE
0 to 10 square feet
(0 to 0.9500 square
meters)
DEFAULT
VALUE
0
The DIM does not
compute duct area.
The area must be
first calculated and
then entered into the
unit.
NONE
All pressure based flow stations need to have a SUP
FLO ZERO established on initial set up. Linear flow
stations with a minimum output of 0 VDC do not need a
SUP FLO ZERO.
SUPPLY FLOW
LOW
CALIBRATION
SETTING
SUP LOW
SETP
The SUP LOW SETP menu item sets the supply damper
position for supply low flow calibration.
0 to 100% OPEN
0% OPEN
SUPPLY FLOW
HIGH
CALIBRATION
SETTING
SUP HIGH
SETP
The SUP HIGH SETP menu item sets the supply damper
position for the supply high flow calibration.
0 to 100% OPEN
100% OPEN
39
40
SUPPLY FLOW MENU (continued)
MENU ITEM
SUPPLY FLOW
LOW
CALIBRATION
SOFTWARE
NAME
SUP LOW
CAL
ITEM DESCRIPTION
The SUP LOW CAL menu items display the currently
measured supply flow rate and the calibrated value for
that supply flow. The supply dampers move to the SUP
LOW SETP damper position for the low calibration. The
calibrated supply flow can be adjusted using the /
keys to make it match a reference measurement.
Pressing the SELECT key saves the new calibration
data.
ITEM RANGE
DEFAULT
VALUE
SUPPLY FLOW
HIGH
CALIBRATION
SUP HIGH
CAL
The SUP HIGH CAL menu items display the currently
measured supply flow rate and the calibrated value for
that supply flow. The supply dampers move to the SP
HIGH SETP damper position for the high calibration. The
calibrated supply flow can be adjusted using the /
keys to make it match a reference measurement.
Pressing the SELECT key saves the new calibration
data.
FLOW STATION
TYPE
FLO STA
TYPE
The FLO STA TYPE item is used to select the flow station
input signal. PRESSURE is selected when TSI flow
stations with pressure transducers are installed. LINEAR
is selected when a linear output flow station is installed.
Typically a thermal anemometer based flow station.
PRESSURE or
LINEAR
PRESSURE
MAXIMUM
FLOW STATION
VELOCITY
TOP
VELOCITY
The TOP VELOCITY item is used to input the maximum
velocity of a linear flow station output. A TOP VELOCITY
must be input for the linear flow station to operate.
0 to 5,000 FT/MIN
(0 to 25.4 m/s)
0
NOTE: This item is disabled if a pressure based flow
station is installed.
Part Two
Technical Section
SUPPLY FLOW MENU (continued)
MENU ITEM
RESET
CALIBRATION
SOFTWARE
NAME
RESET CAL
END OF
MENU
ITEM DESCRIPTION
The RESET CAL menu item zeroes out the calibration
adjustments for the supply flow. When this menu item is
entered, the 8681 prompts you to verify that you want to
do this. Press the SELECT key to reset the calibrations,
and the MENU key to reject it.
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
ITEM RANGE
DEFAULT
VALUE
41
42
EXHAUST FLOW MENU
MENU ITEM
GENERAL
EXHAUST
DUCT SIZE
SOFTWARE
NAME
EXH DCT
AREA
ITEM DESCRIPTION
The EXH DCT AREA item inputs the general exhaust
duct size. The duct size is needed to compute the total
general exhaust flow out of the laboratory. This item
requires a flow station to be mounted in each general
exhaust duct.
If the DIM displays English units, area must be entered in
square feet. If metric units are displayed, area must be
entered in square meters.
EXHAUST
FLOW STATION
ZERO
EXH FLO
ZERO
The EXH FLO ZERO item establishes the flow station
zero flow point. A zero or no flow point needs to be
established in order to obtain a correct flow
measurement output (see Calibration section).
ITEM RANGE
0 to 10 square feet
(0 to 0.9500 square
meters)
DEFAULT
VALUE
0
The DIM does not
compute duct area.
The area must be
first calculated and
then entered into the
unit.
NONE
All pressure based flow stations need to have an EXH
FLO ZERO established on initial set up. Linear flow
stations with a minimum output of 0 VDC do not need a
SUP FLO ZERO.
EXHAUST
FLOW LOW
CALIBRATION
SETTING
EXH LOW
SETP
The EXH LOW SETP menu item sets the general
exhaust damper position for general exhaust low flow
calibration.
0 to 100% OPEN
0% OPEN
EXHAUST
FLOW HIGH
CALIBRATION
SETTING
EXH HIGH
SETP
The EXH HIGH SETP menu item sets the general
exhaust damper position for the general exhaust high
flow calibration.
0 to 100%
100% OPEN
Part Two
Technical Section
EXHAUST FLOW MENU (continued)
MENU ITEM
EXHAUST
FLOW LOW
CALIBRATION
SOFTWARE
NAME
EXH LOW
CAL
ITEM DESCRIPTION
The EXH LOW CAL menu items display the currently
measured general exhaust flow rate and the calibrated
value for that general exhaust flow. The exhaust
dampers move to the EXH LOW SETP damper position
for the low calibration. The calibrated general exhaust
can be adjusted using the / keys to make it match a
reference measurement. Pressing the SELECT key
saves the new calibration data.
EXHAUST
FLOW HIGH
CALIBRATION
EXH HIGH
CAL
The EXH HIGH CAL menu items display the currently
measured general exhaust flow rate and the calibrated
value for that general exhaust flow. The exhaust
dampers moves to the EXH HIGH SETP damper position
for the high calibration. The calibrated general exhaust
flow can be adjusted using the / keys to make it
match a reference measurement. Pressing the SELECT
key saves the new calibration data.
FLOW STATION
TYPE
FLO STA
TYPE
The FLO STA TYPE item is used to select the flow station
input signal. PRESSURE is selected when TSI flow
stations with pressure transducers are installed. LINEAR
is selected when a linear output flow station is installed (05 VDC or 0-10 VDC): Typically a thermal anemometer
based flow station.
MAXIMUM
FLOW STATION
VELOCITY
TOP
VELOCITY
The TOP VELOCITY item is used to input the maximum
velocity of a linear flow station output. A TOP VELOCITY
must be input for the linear flow station to operate.
NOTE: This item is disabled if a pressure based flow
station is installed.
ITEM RANGE
DEFAULT
VALUE
PRESSURE or
LINEAR
PRESSURE
0 to 5,000 FT/MIN
(0 to 25.4 m/s)
0
43
44
EXHAUST FLOW MENU (continued)
MENU ITEM
RESET
CALIBRATION
SOFTWARE
NAME
RESET CAL
END OF
MENU
ITEM DESCRIPTION
The RESET CAL menu item zeroes out the calibration
adjustments for the general exhaust flow. When this
menu item is entered, the 8681 prompts you to verify that
you want to do this. Press the SELECT key to reset the
calibrations, and the MENU key to reject it.
ITEM RANGE
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
*These menu items do not appear on SureFlow controllers provided with BACnet® communications.
DEFAULT
VALUE
Part Two
Technical Section
HOOD FLOW MENU
MENU ITEM
FUME HOOD
EXHAUST
DUCT SIZE
SOFTWARE
NAME
HD1 DCT
AREA
ITEM DESCRIPTION
The HD# DCT AREA item inputs the fume hood exhaust
duct size. The duct size is needed to compute the flow
out of the fume hood. This item requires a flow station to
be mounted in each fume hood exhaust duct.
ITEM RANGE
0 to 10 square feet
(0 to 0.9500 square
meters)
HD2 DCT
AREA*
If the DIM displays English units, area must be entered in
square feet. If metric units are displayed area must be
entered in square meters.
The DIM does not
compute duct area.
The area must be
first calculated and
then entered into the
unit.
HD1 FLO
ZERO
The HD# FLO ZERO item establishes the flow station
zero flow point. A zero or no flow point needs to be
established in order to obtain a correct flow
measurement output (see Calibration section).
and
FUME HOOD
FLOW STATION
ZERO
and
HD2 FLOW
ZERO*
MINIMUM
HOOD #
FLOWS
MIN HD1
FLOW
and
All pressure based flow stations need to have a
HD# FLO ZERO established on initial set up. Linear flow
stations with a minimum output of 0 to 5 VDC do not
need a HD# FLO ZERO.
The MIN HD# FLOW menu items adjust the minimum flow
value for each fume hood input. Use this menu item if the
fume hood flow measurements are too low when the sash
is closed.
MIN HD2
FLOW*
HOOD # LOW
CALIBRATION
POINTS
HD1 LOW
CAL
and
45
HD2 LOW
CAL*
The HD# LOW CAL menu items display the currently
measured fume hood flow rate and the calibrated value
for that fume hood flow. The calibrated hood flow can be
adjusted using the / keys to make it match a
reference measurement. Pressing the SELECT key saves
the new calibration data.
NONE
DEFAULT
VALUE
0
46
HOOD FLOW MENU (continued)
MENU ITEM
HOOD # HIGH
CALIBRATION
POINTS
SOFTWARE
NAME
HD1 HIGH
CAL
and
HD2 HIGH
CAL*
ITEM DESCRIPTION
The HD# HIGH CAL menu items display the currently
measured fume hood flow rate and the calibrated value
for that fume hood flow. The calibrated hood flow can be
adjusted using the / keys to make it match a
reference measurement. Pressing the SELECT key saves
the new calibration data.
ITEM RANGE
DEFAULT
VALUE
FLOW STATION
TYPE
FLO STA
TYPE
The FLO STA TYPE item is used to select the flow station
input signal. PRESSURE is selected when TSI flow
stations with pressure transducers are installed. LINEAR
is selected when a linear output flow station is installed (0
to 5 VDC or 0 to 10 VDC): Typically a thermal
anemometer based flow station.
PRESSURE or
LINEAR
PRESSURE
MAXIMUM
FLOW STATION
VELOCITY
TOP
VELOCITY
The TOP VELOCITY item is used to input the maximum
velocity of a linear flow station output. A TOP VELOCITY
must be input for the linear flow station to operate.
0 to 5,000 FT/MIN
(0 to 25.4 m/s)
0
NOTE: This item is disabled if a pressure based flow
station is installed.
RESET
CALIBRATION
Part Two
RESET CAL
The RESET CAL menu item zeroes out the calibration
adjustments for the hood flow. When this menu item is
entered, the 8681 prompts you to verify that you want to
do this. Press the SELECT key to reset the calibrations
and the MENU key to reject it.
END OF
MENU
The END OF MENU item informs you that the end of a
menu has been reached. You can either scroll back up
the menu to make changes, or press the SELECT or
MENU key to exit out of the menu.
*These menu items do not appear on SureFlow controllers provided with BACnet® communications.
Setup / Checkout
The AOC is easy to program and setup. This section covers the theory of operation, required
software programming, a programming example, and how to verify (checkout) that the
components are functioning correctly. The AOC uses a unique control sequence that combines
flow and pressure differential measurements to maintain air balance and laboratory pressure,
while interfacing with a thermostat to maintain laboratory temperature. The overall AOC control
sequence seems quite complicated initially, but the Theory of Operation section breaks the
sequence down into sub-sequences which simplifies the total system.
Theory of Operation
The AOC control system requires the following measurement inputs to function correctly:

General exhaust flow measured with a flow station (if general exhaust is installed).

Fume hood exhaust flow measured with a flow station.

Supply air flow measured with a flow station.

Temperature measured with a thermostat (if temperature is incorporated into sequence).

Pressure differential with a TSI pressure sensor (if pressure is incorporated into
sequence).
Laboratory Air Balance
Laboratory air balance is maintained by measuring the fume hood exhaust (or other
exhaust), subtracting an offset flow from the fume hood total, and then setting the supply
air damper(s) to maintain the offset between supply air and fume hood exhaust. The
general exhaust damper is normally closed, except when room pressure cannot be
maintained. This may occur when the fume hood sashes are all down and the supply air
is at a minimum position. The general exhaust damper opens to maintain the required
offset and pressure differential.
Pressure Control
The pressure differential signal is sent to the AOC (assumption: laboratory is under
negative pressure). If pressure is at setpoint, the control algorithm does nothing. If
pressure is not at setpoint, the offset value is changed until pressure is maintained, or the
minimum or maximum offset value is reached. If the offset value:
increases, the supply air is reduced until one of three events occur:

Pressure setpoint is reached. The AOC maintains the new offset.

The offset range is exceeded. The offset will be at maximum attempting to reach
pressure setpoint. An alarm triggers to inform you pressure differential is not being
maintained.

Supply air minimum is reached. The general exhaust begins to open (was closed) to
maintain pressure differential.
decreases, the supply air increases until one of three events occur:

Pressure setpoint is reached. The AOC maintains the new offset.

The offset range is exceeded. The offset will be at minimum attempting to reach
pressure setpoint. An alarm triggers to inform you pressure differential is not being
maintained.

Supply air maximum is reached. The alarm triggers to inform you pressure
differential is not being maintained.
Technical Section
47
NOTE: The pressure differential is a slow secondary control loop. The system initially
starts with a calculated offset value and then slowly adjusts the offset value to
maintain pressure differential.
Temperature Control
The Model 8681 receives a temperature input from a temperature sensor (1000 
Platinum RTD). The Model 8681 controller maintains temperature control by:
(1)
Controlling supply and general exhaust for ventilation and cooling
(2)
Controlling the reheat coil for heating
The Model 8681 has three supply flow minimum setpoints. The ventilation setpoint
(VENT MIN SET) is the minimum flow volume required to meet ventilation needs of the
laboratory (ACPH). The temperature supply setpoint (COOLING FLOW) is the theoretical
minimum flow required to meet cooling flow needs of the laboratory. The unoccupied
setpoint (UNOCC SETP) is the minimum flow required when the lab is not occupied. All
of these setpoints are configurable. If the Model 8681 is in the Unoccupied Mode, the
controller will control the supply air flow to the UNOCCUPY SET ventilation rate, the
supply flow will not be modulated for space cooling; space temperature control will be
maintained by modulating the reheat coil.
The Model 8681 continuously compares the temperature setpoint to the actual space
temperature. If setpoint is being maintained, no changes are made. If setpoint is not
being maintained, and the space temperature is rising, the controller will first modulate
the reheat valve closed. Once the reheat valve is fully closed the controller begins a 3minute time period. If, after the 3-minute time period the reheat valve is still fully closed,
the Model 86812 then gradually begins increasing the supply volume by 1 CFM/second
up to the COOLING FLOW setpoint.
The controller, when controlling supply flow for cooling, will not increase the supply flow
above the COOLING FLOW ventilation rate. If the space temperature decreases below
the setpoint, the controller first reduces the supply volume. Once the supply volume
reaches its minimum (VENT MIN SET), the controller then starts a 3-minute time period.
If, after 3 minutes the supply flow is still at the VENT MIN SET flow rate, the controller
begins modulating the reheat coil open to meet the heating demand.
If the general exhaust is in the closed position and fume hood loads require additional
replacement air, the Model 8681 overrides ventilation or temperature setpoints to
modulate supply for pressurization control. Temperature is then controlled by the reheat
valve in this sequence.
The control output items in the DIAGNOSTICS menu shows a percentage value. If
control direction for a given output is set to DIRECT, the diagnostic value will be percent
OPEN. If control direction for a given output is set to REVERSE, the diagnostic value will
be percent CLOSED.
NOTE: The greatest flow requirement dominates the supply flow. If hood replacement air
exceeds the ventilation or temperature flow minimums, the replacement air
requirement is maintained (minimums are ignored).
48
Part Two
In summary, understanding the AOC control algorithm is the key to getting the system functioning
correctly. The AOC control algorithm functions as follows:
SUPPLY AIR =
GENERAL EXHAUST +
FUME HOOD EXHAUST
- OFFSET
Supply air is at
minimum
position; unless
additional
replacement air
is required
(fume hood or
general
exhaust).
General exhaust is
closed or at minimum
position; except when
supply air is at minimum
position and pressure
control cannot be
maintained.
Independent control loop
by fume hood controller
maintains face velocity.
Hood exhaust flow is
monitored by AOC. The
AOC does not control the
fume hood.
Programmed
by user. User
programs
minimum and
maximum
offset.
Required Software Programming
The following menu items must be programmed for the AOC to function. See Menu and Menu
Items section for information in individual menu items.
SUPPLY
FLOW MENU
EXHAUST FLOW
MENU
HOOD FLOW
MENU
SETPOINT
MENU
SUP DCT
AREA
SUP FLO
ZERO
FLO STA TYPE
TOP
VELOCITY
SUP LOW
SETP
SUP HIGH
SETP
SUP LOW CAL
SUP HIGH CAL
EXH DCT AREA
EXH FLO ZERO
FLO STA TYPE
TOP VELOCITY
EXH LOW SETP
EXH HIGH SETP
EXH LOW CAL
EXH HIGH CAL
HD1 DCT AREA
HD2 DCT AREA
HD1 FLO ZERO
HD2 FLO ZERO
FLO STA TYPE
TOP VELOCITY
HD1 LOW CAL
HD1 HIGH CAL
HD2 LOW CAL
HD2 HIGH CAL
MIN OFFSET
MAX OFFSET
NOTE: If temperature or pressure control is being maintained by the AOC, the following menu
items must also be programmed:
- Temperature - The temperature cooling and heating values: VENT MIN SET, TEMP
MIN SET, and TEMP SETP.
- Pressure - The pressure differential value: SETPOINT
There are additional programmable software menu items to tailor the controller to your specific
application or increase flexibility. These menu items are not required to be programmed for the
AOC to operate.
Technical Section
49
Programming Example
The laboratory shown is Figure 7 is being initially setup. The required HVAC information is below
the figure.
Figure 7: Laboratory Setup Example
Laboratory Design
Laboratory size
5 foot fume hood
Flow offset
Ventilation setpoint
Supply Cooling Volume
Pressure differential
Temperature setpoint
= 12’ x 14’ x 10’ (1,680 ft3).
= 250 CFM min* 1,000 CFM max*
= 100 - 500 CFM*
= 280 CFM* (ACPH = 10)
= 400 CFM*
= -0.001 in. H2O*
= 72F
* Value supplied by laboratory designer.
Room Pressure Control System
(1)
(2)
(3)
(4)
(5)
(6)
(7)
50
Model 8681 Adaptive Offset Control System mounted in the laboratory.
A through-the-wall pressure sensor mounted between the corridor (referenced
space) and laboratory (controlled space).
Damper, pressure dependent VAV box or venturi valve with actuator assembly
mounted in supply air duct(s).
Damper, pressure dependent VAV box or venturi valve with actuator assembly
mounted in exhaust air duct.
Flow station mounted in supply air duct. (Required for non-venturi valve
applications only).
Flow station mounted in general exhaust air duct. (Required for non-venturi valve
applications only).
Flow station mounted in fume hood exhaust duct. (Required for non-venturi valve
applications only).
Part Two
Temperature Control System
(1)
(2)
Temperature Sensor (1000 RTD) mounted in the laboratory.
Reheat coil mounted in supply air duct(s).
Fume Hood Control System
(1) Independent SureFlow VAV Face Velocity Control system.
Based on the preceding information, and knowing duct sizes, the following required menu items
can be programmed:
MENU ITEM
ITEM VALUE
DESCRIPTION
SUP DCT AREA
EXH DCT AREA
HD1 DCT AREA
1.0 ft2
0.55 ft2
0.78 ft2
Supply duct area
General exhaust duct area
Fume hood duct area
(12” x 12”)
(10 inch round)
(12 inch round)
MIN OFFSET
100 CFM
Minimum offset.
MAX OFFSET
500 CFM
Maximum offset.
EXH CONFIG
UNGANGED (Default Value)
Additional menu items to program for temperature and pressure control.
VENT MIN SET
COOLING FLOW
280 CFM
400 CFM
10 air changes per hour
Required flow to cool laboratory.
TEMP SETP
72F
Laboratory temperature setpoint.
SETPOINT
–0.001 in. H2O
Pressure differential setpoint.
Sequence Of Operation
Beginning scenario:
Laboratory is maintaining pressure control; -0.001 in. H2O.
Temperature requirement is satisfied.
Fume hood sashes are down, total hood exhaust is 250 CFM.
Supply air is 280 CFM (maintain ventilation).
General exhaust 130 CFM (calculated from below).
Fume hood + General exhaust - Offset = Supply air
250
+
?
- 100 = 280
The fume hood is opened so that the chemists can load experiments into the hood. The face
velocity (100 ft/min) is maintained by modulating the fume hood dampers. The total fume hood
flow is now 1,000 CFM.
Fume hood + General exhaust - Offset = Supply air
1,000
+
0
- 100 = 900
The supply air volume changes to 900 CFM (1,000 CFM hood exhaust - 100 CFM offset). The
general exhaust is closed since no additional exhaust is needed for temperature or ventilation.
However, the Digital Interface Module indicates the laboratory is now - 0.0002 in. H2O (not
negative enough). The AOC algorithm slowly changes the offset until pressure control is
maintained. In this case the offset changes to 200 CFM, which decreases the supply volume by
100 CFM. The additional offset maintains the pressure differential at - 0.001 in. H2O (setpoint).
Fume hood + General exhaust - Offset = Supply air
1,000
+
0
- 200 = 800
Technical Section
51
The hood is shut after the experiments are loaded so the initial conditions prevail.
Fume hood + General exhaust - Offset = Supply air
250
+
130
- 100 = 280
An oven is turned on and the laboratory is getting warm. The thermostat sends the AOC a signal
to switch to temperature minimum (TEMP MIN SET). This increases the supply air to 400 CFM.
The general exhaust air must also increase (damper opens) to maintain flow balance.
Fume hood + General exhaust - Offset = Supply air
250
+
250
- 100 = 400
The control loop continuously keeps the room balance, room pressure, and temperature control
satisfied.
Checkout
The AOC controller should have the individual components checked prior to attempting control of
the laboratory. The checkout procedure outlined below confirms all hardware is performing
correctly. The checkout procedure is not difficult and catches any hardware problems. The steps
are as follows:
Confirm wiring is correct
The most common problem with installed hardware equipment is incorrect wiring. This
problem usually exists on initial installation, or when modifications to the system take
place. The wiring should be very closely checked to verify it exactly matches the wiring
diagram. Polarity must be observed for system to operate correctly. The TSI provided
cables are all color coded to ensure proper wiring. A wiring diagram is located in
Appendix B of this manual. Wiring associated with non TSI components should be
closely checked for correct installation.
Confirming physical installation is correct
All of the hardware components need to be installed properly. Review the installation
instructions and verify components are installed properly at the correct location. This can
be easily confirmed when checking the wiring.
Verifying individual components
Verifying all TSI components are operating correctly requires following a simple
procedure. The fastest procedure involves first checking the DIM, and then confirming all
component parts are functioning.
NOTE: These checks require power to the AOC and all components.
CHECK - DIM
Press TEST key to verify Digital Interface Module (DIM) electronics are functioning
correctly. At the end of the self test, the display shows SELF TEST - PASSED if DIM
electronics are good. If unit displays DATA ERROR at the end of the test, the electronics
may be corrupted. Check all software items to determine cause of DATA ERROR.
52
Part Two
If SELF TEST - PASSED was displayed proceed to check individual components. Enter
Diagnostics and Flow Check Menu to check the following:

Control output - supply (if controlling supply air).

Control output - exhaust (if controlling exhaust air).

Control output - reheat (if controlling reheat valve).

Sensor input (if pressure sensor is installed).

Sensor status (if pressure sensor installed).

Temperature input.

General exhaust flow station.

Supply flow station.

Fume hood flow station.
The menu items are explained in detail in the Menu and Menu Items section of the
manual, so their function is not reviewed here. If the AOC system passes each of the
checks, the mechanical piece parts are all functioning correctly.
CHECK - Control output - supply
Enter CONTROL SUP menu item in diagnostics menu. A number between 0 and 255 is
displayed. Press the / keys until either 0 or 255 shows on the display. Note the
position of the supply air control damper. If display reads 0, press the  key until 255 is
shown on display. If display reads 255, press  key until 0 is shown on display. Note the
position of the supply air damper. The damper should have rotated either 45 or 90
degrees depending on actuator installed.
CHECK - Control output - exhaust
Enter CONTROL EXH menu item in diagnostics menu. A number between 0 and 255 is
displayed. Press the / keys until either 0 or 255 shows on the display. Note the
position of the general exhaust control damper. If display reads 0, press the  key until
255 is shown on display. If display reads 255, press  key until 0 is shown on display.
Note the position of the general exhaust damper. The damper should have rotated either
45 or 90 degrees depending on actuator installed.
CHECK - Control output - temperature
Enter CONTROL TEMP menu item in diagnostics menu. A number between 0 and 255 is
displayed. Press the / keys until either 0 or 255 shows on the display. Note the
position of the reheat valve. If display reads 0, press the  key until 255 is shown on
display. If display reads 255, press  key until 0 is shown on display. Note the position of
the reheat valve. The valve should have rotated either 45 or 90 degrees depending on
actuator installed.
CHECK - Sensor input
Enter SENSOR INPUT menu item in diagnostics menu. A voltage between 0 and 10 volts
DC is displayed. It is not important what the exact voltage is to pass this test. Tape over
the pressure sensor (slide pressure sensor door open) and voltage should read
approximately 5 volts (zero pressure). Remove tape and blow on sensor. Displayed
value should change. If voltage changes, the sensor is functioning correctly. If voltage
doesn’t change, proceed to CHECK - Sensor status.
Technical Section
53
CHECK - Sensor status
Enter SENSOR STAT menu item in diagnostics menu. If NORMAL is displayed, the unit
passes test. If an error message is displayed, go to diagnostics menu section of the
manual, SENSOR STAT menu item for explanation of error message.
CHECK – Temperature sensor input
Enter TEMP INPUT menu item in diagnostics menu. When this item is entered, a
temperature, via a 1000 platinum RTD, is indicated on the display. The exact
temperature displayed is relatively unimportant. It is more important that the temperature
is changing which indicates the sensor is working correctly.
CHECK - Flow station
The Flow Check menu lists all the flow stations that can be installed. Check each flow
station menu item that has a flow station attached. Enter ___ FLOW IN menu item and
the actual flow is displayed. If the flow is correct, no changes need to be made. If flow is
incorrect, adjust the corresponding ___ DCT AREA until actual flow matches flow station
reading.
If unit passed all checks, the mechanical components are physically working.
54
Part Two
Calibration
The calibration section explains how to calibrate and set the elevation for the AOC pressure
sensor and how to zero a flow station.
NOTE: The pressure sensor is factory calibrated and normally does not need to be adjusted.
However, inaccurate readings may be detected if pressure sensor is not installed
correctly, or problems with the sensor exists. Before calibrating, check that the sensor is
installed correctly (usually only a problem on initial set up). In addition, go into
DIAGNOSTICS menu, SENSOR STAT item. If NORMAL is displayed, calibration can be
adjusted. If an error code is displayed, eliminate error code and then verify pressure
sensor needs adjustment.
Adjusting the SureFlow pressure sensor calibration may be required to eliminate errors due to
convection currents, HVAC configuration, or equipment used to make the measurement. TSI
recommends always taking the comparison measurement in the exact same location (i.e., under
the door, middle of door, edge of door, etc.). A thermal air velocity meter is needed to make the
comparison measurement. Normally the velocity is checked at the crack under the doorway, or
the door is opened 1” to allow alignment of the air velocity probe making the measurement. If the
crack under the door is not large enough, use the 1” open door technique.
All pressure transducer based flow stations and 1 to 5 VDC linear flow stations must be zeroed
upon initial system set up. Linear 0 to 5 VDC flow stations do not require a zero flow to be
established.
Calibrating Pressure Sensor
Enter calibration menu (see Software Programming if not familiar with key stroke procedure).
Access code is turned on so enter access code. All menu items described below are found in
CALIBRATION menu.
Elevation
The ELEVATION item eliminates pressure sensor error due to elevation of building. (See
ELEVATION item in Menu and Menu Items section for further information).
Enter the ELEVATION menu item. Scroll through the elevation list and select the one
closest to the building’s elevation.
Press the SELECT key to save the data and exit back to the calibration menu.
Technical Section
55
Figure 8: Pressure Sensor Door Slid Open
Sensor span
NOTE: A smoke test and a comparison measurement by an air velocity meter are
required to calibrate the pressure sensor. The air velocity meter only gives a
velocity reading, so a smoke test must be performed to determine pressure
direction.
WARNING: The span can only be adjusted in the same pressure direction. Adjusting
span cannot cross zero pressure. Example: If unit displays +0.0001 and
actual pressure is -0.0001, do not make any adjustments. Manually change
the air balance, close or open dampers, or open door slightly to get both unit
and actual pressure to read in same direction (both read either positive or
negative). This problem can only occur at very low pressures so slightly
changing the balance should eliminate the problem.
Perform a smoke test to determine pressure direction.
1. Select SENSOR SPAN item.
2. Position thermal air velocity meter in door opening to obtain velocity reading. Press
/ keys until pressure direction (+/-) and sensor span match thermal air velocity
meter, and smoke test.
3. Press SELECT key to save sensor span.
4. Exit menu, calibration is complete.
Flow station pressure transducer zero
NOTE: Not required for linear flow stations with 0 to 5 VDC output.
Pressure based flow station
1. Disconnect tubing between pressure transducer and flow station.
2. Enter menu item that corresponds to flow station: Hood flow, Exhaust Flow, or
Supply flow.
3. Select HD1 FLO ZERO or HD2 FLO ZERO to take a fume hood flow station zero.
or
4. Select EXH FLO ZERO to take a general exhaust flow station zero.
or
5. Select SUP FLO ZERO to take a supply flow station zero.
6. Press SELECT key. Flow zero procedure, which takes 10 seconds, is automatic.
56
Part Two
7. Press SELECT key to save data.
8. Connect tubing between pressure transducer and flow station.
Linear flow station 1 to 5 VDC output
1. Remove flow station from duct, or cutoff flow in duct. Flow station must have no flow
going past the sensor.
2. Enter menu item that corresponds to flow station location: Hood flow, Exhaust Flow,
or Supply flow.
3. Select HD1 FLO ZERO or HD2 FLO ZERO to take a fume hood flow station zero.
or
4. Select EXH FLO ZERO to take a general exhaust flow station zero.
or
5. Select SUP FLO ZERO to take a supply flow station zero.
6. Press SELECT key. Flow zero procedure, which takes 10 seconds, is automatic.
7. Press SELECT key to save data.
8. Install flow station back in duct.
2-Point Flow Calibration
Supply and General Exhaust Flow Calibration:
1. Enter menu that corresponds to flow calibration: Supply Flow, Exhaust Flow.
2. Select SUP LOW SETP to enter a supply flow low calibration setpoint.
or
Select EXH LOW SETP to enter a general exhaust flow low calibration setpoint.
The DIM displays a value between 0% OPEN and 100% OPEN. Press the  or 
keys to adjust the value displayed (and the damper position). Using a voltmeter, read
the input voltage from the appropriate pressure transducer. When the voltmeter
reading is approximately 20% of the full flow reading (100% OPEN) press the
SELECT key to save the data.
then
Select SUP HIGH SETP to enter a supply flow low calibration setpoint.
or
3. Select EXH HIGH SETP to enter a general exhaust flow low calibration setpoint.
The DIM displays a value between 0% OPEN and 100% OPEN. Press the  or 
keys to adjust the value displayed (and the damper position). Using a voltmeter, read
the input voltage from the appropriate pressure transducer. When the voltmeter
reading is approximately 80% of the full flow reading (100% OPEN) press the
SELECT key to save the data.
then
Select SP LOW CAL to enter a supply flow low calibration value.
or
Select EX LOW CAL to enter a general exhaust flow low calibration value.
Technical Section
57
The DIM displays two air flow values. Press the  or  keys to adjust the value
displayed on the right to match the actual measured airflow, which is obtained with a
duct traverse measurement or with a capture hood measurement.
4. Press SELECT key to save data.
then
Select SUP HIGH CAL to enter a supply flow high calibration value.
or
Select EXH HIGH CAL to enter a general exhaust flow high calibration value.
The DIM displays two airflow values. Press the  or  keys to adjust the value
displayed on the right to match the actual measured airflow, which is obtained with a
duct traverse measurement or with a capture hood measurement.
5. Press SELECT key to save data.
Hood Flow Calibration
1. Enter HOOD CAL menu. Raise the fume hood sash, of a previously calibrated fume
hood, from fully closed to an approximate height of 12”. Select the corresponding
HD# LOW CAL menu item.
2. The DIM displays two airflow values. Press the  or  keys to adjust the value
displayed on the right to match the actual airflow, which is obtained with a duct
traverse measurement or by calculating the volumetric flow. Calculated volumetric
flow can be determined by multiplying on the current sash open area by the
displayed face velocity.
3. Press SELECT key to save data.
then
Raise the fume hood sash above the low flow calibration, or to its sash stop
(approximately 18”). Select the corresponding HD# HIGH CAL menu item.
The DIM displays two airflow values. Press the  or  keys to adjust the value
displayed on the right to match the actual airflow, which is obtained with a duct
traverse measurement or by calculating the volumetric flow. Calculated volumetric
flow can be determined by multiplying on the current sash open area by the
displayed face velocity.
4. Press SELECT key to save data.
NOTE:
Insert number of flow calibration you are performing.
A low flow calibration must be performed before its associated high flow
calibration is performed. For example, in a laboratory that has two separate
supply flows, SUP LOW CAL must be completed before SUP HIGH CAL.
It is acceptable to complete all low flow calibrations before completing their
associated high flow calibrations. To continue with the previous example:
HD1 LOW CAL and HD2 LOW CAL could both be completed before
completing HD1 HIGH CAL and HD2 HIGH CAL.
Fume hood face velocity calibration must be completed before beginning
fume hood flow calibration.
58
Part Two
Maintenance and Repair Parts
The Model 8681 SureFlow Adaptive Offset Controller requires minimal maintenance. Periodic
inspection of system components as well as an occasional pressure sensor cleaning are all that
are needed to ensure that the Model 8681 is operating properly.
System Component Inspection
It is recommended that the pressure sensor be periodically inspected for accumulation of
contaminants. The frequency of these inspections is dependent upon the quality of the air being
drawn across the sensor. Quite simply, if the air is dirty, the sensors require more frequent
inspection and cleaning.
Visually inspect the pressure sensor by sliding open the sensor housing door (Figure 9). The air
flow orifice should be free of obstructions. The small ceramic coated sensors protruding from the
orifice wall should be white and free of accumulated debris.
Figure 9: Pressure Sensor Door Slid Open
Periodically inspect the other system components for proper performance and physical signs of
excessive wear.
Pressure Sensor Cleaning
Accumulations of dust or dirt can be removed with a dry soft-bristled brush (such as an artist's
brush). If necessary, water, alcohol, acetone, or trichlorethane may be used as a solvent to
remove other contaminants.
Use extreme care when cleaning the velocity sensors. The ceramic sensor may break if
excessive pressure is applied, if sensor is scraped to remove contaminants, or if the cleaning
apparatus abruptly impacts the sensor.
WARNING:
If you are using a liquid to clean the sensor, turn off power to the Model 8681.
Do not use compressed air to clean the velocity sensors.
Do not attempt to scrape contaminants from the velocity sensors. The velocity
sensors are quite durable; however, scraping may cause mechanical damage
and possibly break the sensor. Mechanical damage due to scraping voids the
pressure sensor warranty.
Technical Section
59
Flow Station Inspection / Cleaning
The flow station can be inspected by removing mounting screws and visually examining probe.
Pressure based flow stations can be cleaned by blowing compressed air into the low and high
pressure taps (flow station does not need to be removed from duct). Linear flow stations (thermal
anemometer type) can be cleaned with a dry soft-bristled brush (such as an artist's brush). If
necessary, water, alcohol, acetone, or trichlorethane may be used as a solvent to remove other
contaminants.
Replacement Parts
All components of the room pressure controller are field replaceable. Contact TSI HVAC Control
Products at (800) 874-2811 (U.S. and Canada) or (001 651) 490-2811 (other countries) or your
nearest TSI Manufacturer's Representative for replacement part pricing and delivery.
Part Number
800776
or
868128
800326
800248
800414
800420
800199
800360
60
Description
8681 Digital Interface Module /
Adaptive Offset Controller
8681-BAC Digital Interface Module /
Adaptive Offset Controller
Pressure Sensor
Sensor Cable
Transformer Cable
Transformer
Controller Output Cable
Electric Actuator
Part Two
Appendix A
Specifications
Dim and AOC Module
Display
Range .................................................................. -0.20000 to +0.20000 inches H2O
Accuracy .............................................................. ±10% of reading, ±0.00001 inches H2O
Resolution ............................................................ 5% of reading
Display Update .................................................... 0.5 sec
Inputs
See Wiring Information Appendix C for
type.
Flow Inputs .......................................................... 0 to 10 VDC .
Temperature Input ............................................... 1000  Platinum RTD
(TC: 385 Ω/100C)
Outputs
Alarm Contact ...................................................... SPST (N.O.)
Max current 2A
Max voltage 220 VDC
Maximum power 60 W
Contacts close in alarm condition
Supply Control ..................................................... 0 to 10 VDC
Exhaust Control ................................................... 0 to 10 VDC
Reheat Control .................................................... 0 to 10 VDC or 4 to 20 mA
RS-485................................................................. Modbus RTU
BACnet® MSTP.................................................... Model 8681-BAC only
General
Operating Temperature ....................................... 32 to 120°F
Input Power ......................................................... 24 VAC, 5 watts max
Dim Dimensions .................................................. 4.9 in. x 4.9 in. x 1.35 in.
Dim Weight .......................................................... 0.7 lb.
Pressure Sensor
Temperature Compensation Range .................... 55 to 95°F
Power Dissipation ................................................ 0.16 watts at 0 inches H2O,
0.20 watts at 0.00088 inches H2O
Dimensions (DxH) ............................................... 5.58 in. x 3.34 in. x 1.94 in.
Weight.................................................................. 0.2 lb.
Damper/Actuator
Types of Actuator ................................................ Electric
Input Power ......................................................... Electric: 24 VAC, 7.5 watts max.
Control Signal Input ............................................ 0 volts damper closed
Time for 90° Rotation........................................... Electric: 1.5 seconds
61
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62
Appendix A
Appendix B
Network Communications
Network communications are available on the Model 8681 and Model 8681-BAC. The Model
8681 can communicate with a building management system through Modbus protocol. The
Model 8681-BAC can communicate with a building management system through BACnet® MSTP
protocol. Please refer to the appropriate section below for more detailed information.
Modbus Communications
Modbus communications are installed in the Model 8681 adaptive offset room pressure
controllers. This document provides the technical information needed to communicate between
the host DDC system and the Model 8681 units. This document assumes the programmer is
familiar with Modbus protocol. Further technical assistance is available from TSI if your question
is related to TSI interfacing to a DDC system. If you need further information regarding Modbus
programming in general, please contact:
Modicon Incorporated (a division of Schneider-Electric)
One High Street
North Andover, MA 01845
Phone (800) 468-5342
The Modbus protocol utilizes the RTU format for data transfer and Error Checking. Check the
Modicon Modbus Protocol Reference Guide (PI-Mbus-300) for more information on CRC
generation and message structures.
The messages are sent at 9600 baud with 1 start bit, 8 data bits, and 2 stop bits. Do not use the
parity bit. The system is set up as a master slave network. The TSI units act as slaves and
respond to messages when their correct address is polled.
Blocks of data can be written or read from each device. Using a block format speeds up the time
for the data transfer. The size of the blocks is limited to 20 bytes. This means the maximum
message length that can be transferred is 20 bytes. The typical response time of the device is
around 0.05 seconds with a maximum of 0.1 seconds.
Unique to TSI
The list of variable addresses shown below skips some numbers in the sequence due to internal
Model 8681 functions. This information is not useful to the DDC system and is therefore deleted.
Skipping numbers in the sequence will not cause any communication problems.
All variables are outputted in English units: ft/min, CFM, or inches H20. The room pressure
control setpoints and alarms are stored in ft/min. The DDC system must convert the value to
inches of water if that is desired. The equation is given below.
Pressure in inches H2O = 6.2*10-8*(Velocity in ft/min / .836)2
RAM Variables
RAM variables use the Modbus command 04 Read Input Registers. RAM variables are read
only variables that correspond to what is shown on the Digital Interface Module (DIM) display.
TSI offers a number of different models, so if a feature is not available on a unit, the variable is
set to 0.
63
Variable
Address
0
1
8681 RAM Variable List
Information Provided to
Master System
Velocity of room pressure
Room pressure
Space
Temperature
Supply Flow Rate
2
Current temperature value
3
Displayed in CFM.
General Exhaust
Flow Rate
4
Hood #1 Flow
Rate
Hood #2 Flow
Rate
Total Exhaust
Flow Rate
Supply Flow
Setpoint
Minimum Supply
Flow Setpoint
General Exhaust
Flow Setpoint
Current Offset
Value
Status Index
5
7
Flow (CFM) measured by the
supply duct flow station
Flow measured by flow station
connected to general exhaust
input
Flow measured by flow station
connected to hood input #1
Flow measured by flow station
connected to hood input #2
Total exhaust out of laboratory
8
Current supply setpoint
Displayed in CFM.
9
Displayed in CFM.
11
Minimum flow setpoint for
ventilation.
Current general exhaust
setpoint
Current offset value
12
Status of SureFlow device
Supply % Open
Exhaust % Open
16
17
Temperature %
Open
Current
Temperature
Setpoint
18
Current supply damper position
Current exhaust damper
position
Current temperature control
valve position
Current temperature control
setpoint
0 Normal
1 Alarm = Low Pressure
2 Alarm = High Pressure
3 Alarm = Max Exhaust
4 Alarm = Min Supply
5 Data Error
6 Emergency Mode
0 to 100% is displayed
0 to 100% is displayed
Variable Name
Room Velocity
Room Pressure
64
6
10
19
Integer DDC System
Receives
Displayed in ft/min.
Displayed in inches H2O.
Host DDC system must
divide value by 100,000 to
report pressure correctly.
Displayed in F.
Displayed in CFM.
Displayed in CFM.
Displayed in CFM.
Displayed in CFM.
Displayed in CFM.
Displayed in CFM.
0 to 100% is displayed
Displayed in F.
Appendix B
EXAMPLE of 04 Read Input Registers function format.
This example read variable addresses 0 and 1 (Velocity and Pressure from 8681).
QUERY
Field Name
Slave Address
Function
Starting Address Hi
Starting Address Lo
No. Of Points Hi
No. Of Points Lo
Error Check (CRC)
(Hex)
01
04
00
00
00
02
--
RESPONSE
Field Name
Slave Address
Function
Byte Count
Data Hi Addr0
Data Lo Addr0
Data Hi Addr1
Data Lo Addr1
Error Check (CRC)
(Hex)
01
04
04
00
64 (100 ft/min)
00
59 (.00089 “H2O)
--
XRAM Variables
These variables can be read using Modbus command 03 Read Holding Registers. They can be
written to using Modbus command 16 Preset Multiple Regs. Many of these variables are the
same “menu items” that are configured from the SureFlow controller keypad. The calibration and
control items are not accessible from the DDC system. This is for safety reasons, since each
room is individually setup for maximum performance. TSI offers a number of different models, so
if a feature is not available on a unit, the variable is set to 0.
Variable
Address
0
8681 XRAM Variable List
Input Provided to Master
System
Current software version
Integer DDC System
Receives
1.00 = 100
1
SureFlow Model
6 = 8681
2
Emergency Mode Control
Occupancy Mode
3
Occupancy mode device is in
Pressure Setpoint
4
Pressure control setpoint
Ventilation
Minimum Supply
Flow Setpoint
Cooling Flow
Setpoint
Unoccupied
Minimum Supply
Flow Setpoint
Maximum Supply
Flow Setpoint
Minimum Exhaust
Flow Setpoint
5
Minimum supply flow control
setpoint in normal mode
0 Leave emergency
mode
1 Enter emergency
mode
Value returns a 2 when
read
0 Occupied
1 Unoccupied
Displayed in feet per
minute.
Displayed in CFM.
6
Minimum supply flow control
setpoint in temperature mode
Minimum supply flow control
setpoint in unoccupied mode
Displayed in CFM.
Maximum supply flow control
setpoint
Minimum exhaust flow control
setpoint
Displayed in CFM.
Variable Name
Software Version
(read only)
Control Device
(read only)
Emergency Mode*
7
8
9
Network/Modbus Communications
Displayed in CFM.
Displayed in CFM.
65
Occupied
Temperature
Setpoint
Minimum Offset
Maximum Offset
Low Alarm Setpoint
10
8681 XRAM Variable List
Occupied Mode Temperature
setpoint
11
12
13
Minimum offset setpoint
Maximum offset setpoint
Low pressure alarm setpoint
High Alarm Setpoint
14
High pressure alarm setpoint
Minimum Supply
Alarm
Maximum Exhaust
Alarm
Units
15
Minimum supply flow alarm
Displayed in CFM.
Displayed in CFM.
Displayed in feet per
minute.
Displayed in feet per
minute.
Displayed in CFM.
16
Maximum general exhaust alarm
Displayed in CFM.
22
Current pressure units displayed
Unoccupied
Temperature
Setpoint
75
Unoccupied Mode Temperature
setpoint
0 Feet per minute
1 meters per second
2 inches of H2O
3 Pascal
Displayed in F.
Displayed in F.
EXAMPLE of 16 (10 Hex) Preset Multiple Regs function format:
This example changes the setpoint to 100 ft/min.
QUERY
Field Name
Slave Address
Function
Starting Address Hi
Starting Address Lo
No. Of Registers Hi
No. Of Registers Lo
Data Value (High)
Data Value (Low)
Error Check (CRC)
(Hex)
01
10
00
04
00
01
00
64
--
RESPONSE
Field Name
Slave Address
Function
Starting Address Hi
Starting Address Lo
No. of Registers Hi
No. of Registers Lo
Error Check (CRC)
(Hex)
01
10
00
04
00
01
--
Example of 03 Read Holding Registers function format:
This example reads the minimum ventilation setpoint and the minimum temperature setpoint.
QUERY
Field Name
Slave Address
Function
Starting Address Hi
Starting Address Lo
No. Of Registers Hi
No. Of Registers Lo
Error Check (CRC)
66
(Hex)
01
03
00
05
00
02
--
RESPONSE
Field Name
Slave Address
Function
Byte Count
Data Hi
Data Lo
Data Hi
Data Lo
Error Check (CRC)
(Hex)
01
03
04
03
8E (1000 CFM)
04
B0 (1200 CFM)
Appendix B
8681 BACnet® MS/TP Protocol Implementation Conformance
Statement
Date: April 27, 2007
Vendor Name: TSI Inc.
Product Name: SUREFLOW Adaptive Offset Controller
Product Model Number: 8681-BAC
Applications Software Version: 1.0
Firmware Revision: 1.0
BACnet Protocol Revision: 2
Product Description:
TSI SureFlow Room Pressure Controls are designed to maintain more exhaust from a laboratory
than is supplied to it. This negative air balance helps ensure that chemical vapors cannot diffuse
outside the laboratory, complying with requirements in NFPA 45-2000 and ANSI Z9.5-2003. The
SureFlow controller Model 8681 also controls the temperature of the laboratory space by
modulating reheat and the supply air volume. Optionally, a room pressure sensor can be
connected to the SureFlow Model 8681 controller to correct long-term changes in the building
dynamics. This model controller is capable of acting as a stand-alone device or as part of a
building automation system via BACnet MS/TP protocol.
BACnet Standardized Device Profile (Annex L):
 BACnet Operator Workstation (B-OWS)
 BACnet Building Controller (B-BC)
 BACnet Advanced Application Controller (B-AAC)
 BACnet Application Specific Controller (B-ASC)
 BACnet Smart Sensor (B-SS)
 BACnet Smart Actuator (B-SA)
List all BACnet Interoperability Building Blocks Supported (Annex K):
DS-RP-B
DM-DDB-B
DS-WP-B
DM-DOB-B
DS-RPM-B
DM-DCC-B
Segmentation Capability:
Segmented requests not supported
Segmented responses not supported
Network/Modbus Communications
67
Standard Object Types Supported:
Dynamically
Createable
Dynamically
Deletable
Optional
Properties
Supported
Analog Input
Analog Value
No
No
No
No
Binary Input
No
No
Binary Value
No
No
Multi-state
Input
Multi-state
Value
Device Object
No
No
Active_Text,
Inactive_Text
Active_Text,
Inactive_Text
State_Text
No
No
State_Text
No
No
Writable Properties
(Data Type)
Present_Value
(Real)
Present_Value
(Enumerated)
Present_Value
(Unsigned Int)
Object Name
(Char String)
Max Master
(Unsigned Int)
Data Link Layer Options:
 BACnet IP, (Annex J)
 BACnet IP, (Annex J), Foreign Device
 ISO 8802-3, Ethernet (Clause 7)
 ANSI/ATA 878.1, 2.5 Mb. ARCNET (Clause 8)
 ANSI/ATA 878.1, RS-485 ARCNET (Clause 8), baud rate(s)
 MS/TP master (Clause 9), baud rate(s): 76.8k 38.4k, 19.2k, 9600 bps
 MS/TP slave (Clause 9), baud rate(s):
 Point-To-Point, EIA 232 (Clause 10), baud rate(s):
 Point-To-Point, modem, (Clause 10), baud rate(s):
 LonTalk, (Clause 11), medium:
 Other:
Device Address Binding:
Is static device binding supported? (This is currently necessary for two-way communication with
MS/TP slaves and certain other devices.) Yes  No
Networking Options:
 Router, Clause 6 - List all routing configurations, e.g., ARCNET-Ethernet, Ethernet-MS/TP, etc.
 Annex H, BACnet Tunneling Router over IP
 BACnet/IP Broadcast Management Device (BBMD)
Character Sets Supported:
Indicating support for multiple character sets does not imply that they can all be supported
simultaneously.
 ANSI X3.4
 ISO 10646 (UCS-2)
 IBM®/Microsoft® DBCS
 ISO 10646 (UCS-4)
 ISO 8859-1
 JIS C 6226
If this product is a communication gateway, describe the types of non-BACnet
equipment/networks(s) that the gateway supports:
Not Applicable
68
Appendix B
Model 8681-BAC BACnet® MS/TP Object Set
Object
Type
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Input
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Analog
Value
Device
Instance
1
*Units
ft/min, m/s, in. H2O,
Pa
2
cfm, l/s
3
cfm, l/s
4
cfm, l/s
5
cfm, l/s
6
cfm, l/s
7
cfm, l/s
8
°F, °C
9
% Open
10
% Open
11
% Open
1
2
3
4
ft/min, m/s, in. H2O,
Pa
ft/min, m/s, in. H2O,
Pa
ft/min, m/s, in. H2O,
Pa
5
cfm, l/s
6
cfm, l/s
7
cfm, l/s
8
cfm, l/s
9
cfm, l/s
10
cfm, l/s
11
cfm, l/s
12
cfm, l/s
13
cfm, l/s
14
°F, °C
Network/Modbus Communications
Description
Room Pressure
Supply Flow Rate
Supply Flow Setpoint
General Exhaust Flow
Rate
General Exhaust Flow
Setpoint
Hood Flow Rate
Current Flow Offset
Temperature
Supply Damper
Position
Exhaust Damper
Position
Reheat Valve Position
MAC Address
1 to 127
Room Pressure
Setpoint
Low Pressure Alarm
Vent Min Setpoint
-0.19500 to 0.19500
in. H2O
-0.19500 to 0.19500
in. H2O
-0.19500 to 0.19500
in. H2O
0 to 30,000 cfm
Cooling Flow Setpoint
0 to 30,000 cfm
Unocc Flow Setpoint
0 to 30,000 cfm
Max Supply Setpoint
0 to 30,000 cfm
Min Exhaust Setpoint
0 to 30,000 cfm
Min Offset
0 to 30,000 cfm
Max Offset
0 to 30,000 cfm
Min Supply Alarm
0 to 30,000 cfm
Max Exhaust Alarm
0 to 30,000 cfm
Temperature Setpoint
50 to 85 °F
High Pressure Alarm
69
Object
Type
Analog
Value
Binary
Value
Multi-State
Input
Device
Instance
*Units
15
°F, °C
1
Description
Unocc Temp Setpoint
Occ/Unocc Mode
Status Index
1
Multi-State
Value
Multi-State
Value
Emergency Mode
2
Units Value
3
50 to 85 °F
0
1
1
2
3
4
5
6
7
1
2
3
1
2
3
4
Occupied
Unoccupied
Normal
Low Press Alarm
High Press Alarm
Max Exhaust Alarm
Min Supply Alarm
Data Error
Emergency
Exit Emergency Mode
Enter Emergency Mode
Normal
ft/min
m/s
in. H2O
Pa
Device
868001**
TSI8681
* The units are based on the value of the Units Value object. When the Units Value is set to 1 or 3
the units are in English form. When the Units Value is set to 2 or 4 the units are metric. English is
the default value.
** The device instance is 868000, summed with the MAC address of the device.
70
Appendix B
Appendix C
Wiring Information
Back Panel Wiring
1, 2
Input / Output /
Communication
DIM / AOC
Input
3, 4
5, 6
7, 8
9, 10
Output
Input
Communications
Output
PIN #
11, 12
13, 14
Input
Output
15, 16
Communications
17, 18
Output
19, 20
Input
21, 22
23, 24
25, 26
Input
Input
Output
27, 28
Input
Description
24 VAC to power Digital Interface Module (DIM).
NOTE: 24 VAC becomes polarized when connected to
DIM.
24 VAC power for Pressure Sensor
0 to 10 VDC pressure sensor signal
RS-485 communications between DIM and pressure sensor
0 to 10 VDC, general exhaust control signal. 10 VDC = open
(n.o. damper)
- See menu item CONTROL SIG
0 to 10 VDC flow station signal - fume exhaust (HD1 FLOW IN).
Alarm relay - N.O., closes in low alarm condition.
- See menu item ALARM RELAY
RS - 485 communications; AOC to building management
system.
0 to 10 VDC, supply air control signal. 10 VDC = open (n.o.
damper)
- See menu item CONTROL SIG
0 to 10 VDC flow station signal - General exhaust (EXH FLOW
IN) .
0 to 10 VDC flow station signal - Supply air (SUP FLOW IN).
1000 platinum RTD temperature input signal
0 to 10 VDC, reheat valve control signal. 10 VDC = open (n.o.
damper)
- See menu item REHEAT SIG
0 to 10 VDC flow station signal - fume exhaust (HD2 FLOW IN).
BACnet® MSTP communications to building management
system.
WARNING: The wiring diagram shows polarity on many pairs of pins: + / -, H / N, A / B. Damage
to DIM may occur if polarity is not observed.
NOTE:
Terminals 27 & 28 are utilized for BACnet® MSTP communications for Model 8681BAC.
The Model 8681-BAC controller cannot accept a second fume hood flow input; and
all second fume hood flow menu items will be deleted from the menu structure.
71
WARNING:
Controller must be wired exactly as wire diagram shows. Making
modifications to the wiring may severely damage the unit.
Figure 10: Adaptive Offset Wiring Diagram - Damper System with Electric Actuator
72
Appendix C
WARNING: Controller must be wired exactly as wire diagram shows. Making
modifications to the wiring may severely damage the unit.
Figure 11: Offset (Flow Tracking) Wiring Diagram - Damper System with Electric Actuator
Wiring Information
73
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74
Appendix C
Appendix D
Access Codes
There is one access code for all menus. Each menu can have the access code ON or OFF. IF on
the access code must be entered. Pressing the key sequence below allows access to the menu.
The access code must be entered within 40 seconds and each key must be pressed within 8
seconds. Incorrect sequence will not allow access to the menu.
Key #
ACCESS CODE
1
Emergency
2
Mute
3
Mute
4
Menu
5
Aux
75
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76
Appendix D
TSI Incorporated – Visit our website www.tsi.com for more information.
USA
UK
France
Germany
Tel: +1 800 874 2811
Tel: +44 149 4 459200
Tel: +33 4 91 11 87 64
Tel: +49 241 523030
P/N 1980476 Rev. E
India
China
Singapore
©2013 TSI Incorporated
Tel: +91 80 67877200
Tel: +86 10 8251 6588
Tel: +65 6595 6388
Printed in U.S.A.
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