Installation & Operation Guide

KMD-5540 CommTalk Protocol Interface

908-019-01C
1
Introduction
This section provides an overview of the KMD-5540 CommTalk Protocol Interface.
Illustration 1 shows the major components and their locations.

RS-232 Terminals

RJ-12 Connectors

KMC
RX1 TX1 GND

RX2 TX2 GND

KMDIGITAL

Isolation
KMC KMDIGITAL
CommTalk
Lamps
KMC KMDIGITAL
Protocol
Interface
ON

KMC
Network

ON OFF
Network
Switch Switch
OFF

KMDIGITAL
LAMPS

KMC
RDY COM

Status Isolation

LAMPS
LEDs KMDIGITAL Lamps

KMC
B1

COM RDY
RS-485 Status
KMDIGITAL
A1 GND GND

Conn. LEDs

KMC

A2 GND
KMDIGITAL
Power RS-485
~

KMC Conn.

B2
24VAC
PWR

KMD-5540
Power ____ KMC CONTROLS
Jumper

Illustration 1—Controller Components

Installation
This section provides important instructions and guidelines for installing the
KMD-5540. Carefully review this information prior to attempting installation.

Note:
The actual configuration of the interface will depend on the model. KMDigital
connections are made to the left side of the interface and third-party equipment is
connected on the right side.

Mounting
Use the four mounting holes to securely mount the interface inside a UL-approved
Enclosed Energy Management Equipment Panel or other suitable protective enclo-
sure. See Illustration 2—Mounting Hole Locations on page 3.

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KMD-5540 CommTalk Protocol Interface Installation & Operation Guide Installation

6.0"

RX1 TX1 GND

RX2 TX2 GND

ON

ON OFF
OFF
4.0"

LAMPS
RDY COM

LAMPS
B1

COM RDY
A1 GND GND

A2 GND
~

B2
24VAC
PWR Illustration 2—Mounting Hole Locations

Input Connections
The following sections describe the input connections that can be made to the
KMDigital input side of the interface. See the site plan wiring diagrams for specific
requirements.

RS-232 (EIA-232) Inputs

RS-232 inputs are connected to the terminal in the upper left corner of the inter-
face.

Detail
As a general rule in RS-232 wiring, the Red lead is the Receive (Rx) lead and the
Black wire is the Transmit (Tx) lead.

Connect the appropriate leads to the indicated connectors on the terminal.

RS-485 (EIA-485) Inputs

Make connections to a network using the RS-485 connector.

Detail
An End-of-Line connection will have only one wire attached to the A and B termi-
nals. See EOL (End Of Line) Setting on page 5 for EOL switch setting.
◆ Use 18 gauge, twisted-pair, shielded cable with capacitance of no more than
about 50 picofarads per foot for all network wiring. Belden cable model #82760
meets KMC requirements.
◆ Connect the nodes of the network in a daisy-chain arrangement. This means
connecting the A terminal in parallel with all other A terminals and connecting
the B terminal in parallel with all other B terminals.
◆ Connect the shields of the cable together at each controller.
◆ Connect the shields to an earth ground only at one end of the segment; tape
back the shield ground at the other end.

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Installation KMD-5540 CommTalk Protocol Interface Installation & Operation Guide

Output Connections
Output connections are made to the connectors on the right side of the interface.
The actual connectors that appear here depend on the KMD-5540 model.

Illustrations 3 through 7 show wiring configurations for typical implementations

of the interface.

RX1

TX2 GND
TX 7
COMPUTER

TX1 GND
B GND 3

RX2
RX 2

TX
COMPUTER
A GND

RX

KMD-5540-002 INPUT KMD-5540-002 Output

(COM 1) (COM 2) CARRIER DATALINK Input
(COM 2)
KMD-5210
COMPUTER PORT

Illustration 3—KMD-5540-002 Carrier Datalink Configuration

CommTalk Module

RX2 TX2 GND

RX1 TX1

TX
COMPUTER
B GND
GND

RX

TX
COMPUTER
A GND

RX RX TX GND

KMD-5540-003 INPUT KMD-5540-003 OUTPUT

KMD-5210 OUTPUT (COM 1) (COM 2) MICRO
COMPUTER PORT
GATEWAY

Illustration 4—KMD-5540-003 Micro Gateway Configuration

CommTalk Module Jumper to right

XXX

CTS
RX1 TX1 GND

GND
RX2 TX2 GND

TX
COMPUTER GND TX
B
RX
RX

TX XXX
COMPUTER
GND XXX
A
RX

YORKTALK XL INPUT
(PORT 2)

KMD-5210 OUTPUT KMD-5540-003 INPUT KMD-5540-003 OUTPUT

COMPUTER PORT (COM1) (COM 2)

Illustration 5—KMD-5540-003 York Configuration

CommTalk Module
GND

RX2 TX2 GND

B1

7
A1 GND GND
B

2
A

KMD-5540-004 INPUT KMD-5540-004 Output

McQuay MicroTech
(COM 1) (COM 2)
OPM Interface
KMC TIER 2
(COM)
NETWORK OUTPUT

Illustration 6—KMD-5540-004 McQuay MicroTech OPM Configuration

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KMD-5540 CommTalk Protocol Interface Installation & Operation Guide Installation

RS-232

RX2 TX2 GND

CommTalk Module

- + GND

GND

B1
RS-485

A1 GND GND

A2 GND
B
A

B2
- + GND
KMD-5540-005 INPUT KMD-5540-005 OUTPUT
(COM1) (COM 2)

KMC TIER 2 ModBus

NETWORK INPUT
OUTPUT PANEL

Illustration 7—KMD-5540-005 ModBus Configuration

EOL (End Of Line) Setting

RS-485 EOL
SWITCHES

Illustration 8—RS-485 EOL Switches

To set or confirm the EOL termination for the RS-485 connection, see Illustration 7
to locate the switches for these settings.

Proceed as follows:
1. Remove the screw at the center of the interface that secures the cover and
remove the cover.
2. Locate the appropriate switch (see Illustration 8).
3. If the RS-485 connection is the End-of-Line (one set of wires under the RS-485
terminals), verify that both switches on the RS-485 switch assembly are in the
ON position. Otherwise, the switches should be in the OFF position.
4. After you set/confirm the switches, reinstall the cover and screw.

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 Power Connection
Connect the 24 VAC supply voltage (Class 2 transformer only) to the power ter-
minals on the lower left side of the controller. Connect the neutral lead from the
transformer to the GND terminal and the AC phase lead to the ~ (phase) termi-
nal. Power is applied to the KMD-5540 when the transformer is plugged in and the
power jumper is in place (see Illustration 1—Controller Components on page 2).

Configuration
Prior to operating the KMD-5540, it must be configured using the Hardware Con-
figuration Manager (HCM) application supplied with WinControl. See the Win-
Control XL User’s Manual for additional information.

Note:
All devices on the same network must be configured for the same baud rate.

Operation
Once configured, programmed, and powered up, the interface requires very little
user intervention.

Controls and Indicators

The following sections describe the controls and indicators found on the device.

Network ON/OFF
The network ON/OFF switch is located below the modular jack on the left side of
the controller. Use this switch to enable or disable the RS-485 network connection.

Alternately, you may remove the RS-485 terminal block from the pins to complete-
ly isolate the KMD-5540 from the network.

Status LEDs
Two status LEDs are located on the left side of the controller above the power con-
nector terminal. They are used to indicate the following:

RDY – The Ready LED blinks rapidly whenever the controller is operating nor-
mally. You can consider this the same as a power LED.

COM – The Communications LED indicates when the controller is transmitting

over the RS-485 network connection.

Isolation Lamps
Two isolation lamps are located near the Network ON/OFF switch. These lamps
serve three functions:

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KMD-5540 CommTalk Protocol Interface Installation & Operation Guide Operation

◆ Removing the lamps will open the RS-485 circuit and isolate the KMD-5540
from the network.
◆ If one or both lamps are lit, it indicates the network is improperly phased. This
means that the ground potential of the KMD-5540 is not the same as other de-
vices on the network
◆ If the voltage or current on the network exceeds safe levels, the lamps operate as
fuses to protect the KMD-5540 from damage.

Resetting the Controller

If the KMD-5540 appears to be operating incorrectly, or is not responding to com-
mands, you may need to reset it.

Note
Resetting the interface will restore the factory default configuration.

It may be necessary to re-configure the KMD-5540 with HCM to establish normal

communications and operation.

To reset the KMD-5540, proceed as follows.

1. Remove the screw at the center of the the cover and remove the cover.
2. Locate the jumper block next to the input pull-up switches (see Illustration 9).

RESET
JUMPER

Illustration 9—Reset Jumper Block

3. Remove power to the KMD-5540.

4. Place a short on the RST pins. Use a jumper if a spare is available.
5. Power up the KMD-5540. Wait until the RDY LED begins to flash normally.
6. Remove power to the KMD-5540.
7. Remove the short from the RST jumper.
8. Reinstall the cover and screw.
9. Power up the KMD-5540 and re-configure it if necessary.

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Important Notices
The material in this document is provided for information purposes only.
The contents and the product(s) described herein are subject to change with-
out notice. KMC Controls, Inc. makes no representations or warranties with
respect to this document. In no event shall KMC Controls, Inc. be liable for
any damages, direct or incidental, arising out of or related to the use of this
document.

No part of this publication may be reproduced, transmitted, transcribed,

stored in a retrieval system, or translated into any language in any form by
any means without the written permission of KMC Controls, Inc.

Printed in U.S.A.

The KMC logo and CommTalk are trademarks of KMC Controls, Inc.

© 2013, KMC Controls, Inc. All rights reserved.

KMC Controls
19476 Industrial Drive
New Paris, IN 46553
U.S.A.
TEL: 574.831.5250
FAX: 574.831.5252
Email: info@kmccontrols.com

8 908-019-01C