Trane Tracer ZN524 Installation Owner Diagnostics
Installation
Owner
Diagnostics
Tracer®ZN524 for
water-source heat pumps
Order No: CNT-SVX11A-EN Date: August 2003
CNT-SVX11A-EN
2 UV-SVN001-EN
Notice
Notice
Warnings and Cautions appear at appropriate sections throughout this manual.
Read these carefully.
- Indicates a potentially hazordous situation
which, if not avoided, could result in death or
serious injury
WARNING
CAUTION
- Indicates a potentially hazordous situation
which, if not avoided, could result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
CAUTION
- Indicates a situation that may result in
equipment or property damage only accidents.
Contents
CNT-SVX11A-EN 3
Start-up Procedures 4
General Information 5
Control Circuit Board Features 6
Control Features 7
Communication Configurations 8
Installation and Wiring 10
Typical Wiring Diagram— 18
Waterside Ecomomizer
Typical Wiring Diagram— 19
Hot Gas Reheat
Configuration 20
Location Identifier 23
Unit Operation 24
Troubleshooting 32
Replacing Circuit Boards 42
Appendix 43
Appendix—Binary Configuration 44
Appendix—Unit Operation 45
Appendix—Data Lists 47
Appendix—Location Identifier 48
Start-up Procedures
4 CNT-SVX11A-EN
Installation of New Units
WARNING
Hazardous Voltage!
Disconnect all electric power, including
remote disconnects before servicing.
Follow proper lockout/tagout procedures to ensure the power can not be
inadvertently energized. Failure to disconnect power before servicing could
result in death or serious injury.
1. Follow all instruction for installation
of the water-source heat pump as
detailed in the unit’s installation guide.
(Installation Operation Diagnostics
manual).
2. Disconnect power or disable the circuit breaker to unit.
3. Run communication link wire when
required. (See wiring diagram in the
unit).
4. Install zone sensor when required.
(See wiring diagram in the unit and
zone sensor submittals).
5. Reapply power.
6. Check for GREEN Status LED operation to ensure power has been made
to the Tracer
TM
ZN524 unit controller.
7. Check for YELLOW Comm LED operation to help ensure communication has
been made to the Tracer ZN524 unit
controller when applicable.
8. Write the Unit Identification number,
using the IDENTIFICATION TAG on the
unit, in the Appendix of this document,
or on building plans for future location
use.
Power Up Sequence
Manual output test can be initiated at
any time in the power up sequence or
during normal operation.
When 24 VAC power is initially applied
to the controller, the following
sequence occurs:
1. Green Status LED turns on.
2. All outputs are controlled Off.
3. The controller reads input values to
determine initial values.
4. Stand-alone control is assumed
unless occupancy data is communicated.
5. Random start timer expires (5 to 30
seconds, random).
6. Power-up control Wait feature is
applied. When power up control Wait is
enabled, the controller waits 2-minutes
to allow ample time for communicated
control data to arrive. If, after 2-minutes, the controller does not receive a
communicated occupancy request, the
unit assumes standalone operation.
7. All valves and damper calibrate
closed.
8. Normal operation begins after 290
(potentially) seconds have passed.
Note: Manual output test can be
initiated at any time.
General Information
CNT-SVX11A-EN 5
Tracer® ZN524 Overview
The Trane Tracer® ZN524 controller is a
factory-installed and commissioned,
direct-digital controller (DDC) offering
for single or dual compressor watersource heat pump systems. (See Figure
1: “Tracer ZN524 Control Board”)
Trane offers a complete solution to
space comfort control with the flexibility of Integrated Comfort System (ICS)
and stand-alone control packages. The
ICS control package combines HVAC
equipment and building management
into one environmental comfort system.
Integrating the Tracer ZN524 on watersource heat pumps and tying them to a
Tracer Summit® system will provide a
complete building management system. The stand-alone control package
offers the features and functionality of
the direct digital control without a
front-end building automation system,
while providing future considerations
for ICS.
Equipment problems can often be diagnosed on each unit without having to
access the unit componets. These diagnostics can be received remotely via a
modem with a Tracer Summit building
automation system, thus reducing the
number of actual on-site service calls;
through the Rover® service tool connected to a communication jack located
inside the Trace zone sensor; or connected to the unit.
The Tracer ZN524 is factory-mounted,
tested, wired, configured and commissioned for the selected application.
The Tracer ZN524 configuration has
flexible point and product configurations. For example, with point configuration, a specific binary point can be
configured to accept input from either a
time clock or some type of generic
device.
Figure 1: Tracer ZN524 control board
Controller Circuit Board
and Features
6 CNT-SVX11A-EN
Figure 2: Tracer ZN524 unit controller circuit board
A
B
E
D
C
H
F
G
Controller features:
A. Power Connections
B. Generic Connections (BOP)
C. Status LED
D. Auto Test Button
E. Zone Sensor Connections
F. Service Button/LED
G. Communications Connections
H. Communications LED
CNT-SVX11A-EN 7
Controller Features
Each Tracer ZN524 unit controller circuit
board is equipped with enhancements
to help facilitate service, testing, and
diagnosis.
Each board has:
• Manual test button,
• Status LED,
• Communication status LED,
• Service button,
• Quick terminal connectors, and
• Easy to read screen printing. (See
Figure 2: Page 6).
Service
The Trane Tracer ZN524 unit controller is
serviced using Rover®, the software
service tool. Rover is designed to support the Tracer ZN524 unit controller on
a single or dual compressor watersource heat pump.
For “remote” access to the communicating units, the zone sensors offered
with the Tracer ZN524 have a telephone
style (RJ-11) connector allowing field
connection between Rover and the zone
sensor; however, the RJ-11 connector
must be connected to the communications terminals on the Tracer ZN524 unit
controller.(See Figure 3: “Rover service
tool connected to the RJ-11 communication jack in a zone sensor”)
The zone sensor may also be used
when trying to locate a unit. By pressing the on button on the zone sensor
for 5 seconds or using the “wink” command in Rover, the circuit board
receives the signal causing the status
LED to “wink.” Winking allows visual
identifier on the board for service technicians.
The Tracer ZN524 also includes features
such as a test output to manually test
all of the end devices. (See “Manual
Output Test” on page 32, for more information.)
Typical Components
A typical water-source heat pump system with a DDC package consists of the
following physical components, in addition to the mechanical equipment:
• Tracer ZN524—contains the sensor
input circuits, service adjustments,
microprocessor control electronics,
and communications hardware. Power
is supplied by a separately mounted
24 VAC transformer.
• Sensor Modules—a variety of analog
sensors that provide temperature and
optional humidity sensing and CO2
sensor; and an operator interface to
the Tracer ZN524 for operating
modes, status, and temperature set
points.
• Standard End Devices—a variety of
devices that help to gather information and control capacity are used by
the Tracer ZN524 in its control
algorithm to condition the space to
the desired temperature and relative
humidity level.
Note: The Tracer ZN524 is a configured controller. It will not operate
without a valid downloaded configuration file.
The Tracer ZN524 controller supports
ICS and peer-to-peer communications
as well as stand-alone operation. A
number of control features may be configured at the factory or by using the
Rover service tool.
(See “Configuration” on page 20, for
more information.)
Figure 3: Rover service tool connected to the RJ-11
communication jack in a zone sensor
Communication Configurations
8 CNT-SVX11A-EN
Integrated Comfort System
Note: The Tracer ZN524 controller
may only be used with Tracer
Summit version 11.0 or greater
with a Comm5 communications
card.
Water-source heat pumps can operate
as part of a large building automation
system controlled by Tracer Summit.
The Tracer ZN524 is linked directly to
the Tracer Summit via a twisted pair
communication wire. Each Tracer
Summit building automation system
can connect to a maximum of 120
Tracer ZN524 controllers.
Communications link wire
The ICS system allows for complete
communication with the water-source
heat pumps via Tracer ZN524 unit controller. All points connected to the
Tracer ZN524 may be observed from
the Tracer Summit front-end controller.
The Tracer Summit can also initiate an
alarm on a loss of performance or
equipment malfunctions.
The ICS system also allows all of the
water-source heat pumps to share information without the presence of hardwired sensors at each unit. Some typical shared points include outside air
temperature, entering water temperature, and occupancy schedules.
Peer-to-Peer Communications
On a peer-to-peer communication system, multiple Tracer ZN524 controllers
may share data, via a twisted pair communication wire, without the need for a
Tracer Summit system. (See Figure 5:
“Peer-to-peer communication connections”)
Peer-to-peer communications allows
features such as master/slave operation, in which multiple units operate off
of a single zone sensor. This is typically
seen in large spaces requiring multiple
units.
The Rover service tool is required to set
up peer-to-peer communications.
Figure 4: Communications link wire
Figure 5: Peer-to-peer communication connections
Twisted pair wire used in
installation of controller in
water-source heat pump
CNT-SVX11A-EN 9
Communication Interface
Important! To help ensure optimal
performance of the Rover service
tool, please use the latest version.
To obtain the latest version contact your local Trane sales representative or service technician.
Note: Refer to the Tracer system
manuals for more information on
communications.
The Tracer ZN524 communicates via
Comm5 (LonTalk) to a building management system, the Rover service
tool, and other unit controllers on the
communications link. Each Tracer
ZN524 requires a unique address for
the system to operate properly. Every
Tracer ZN524 has this address (Neuron
ID) embedded in the microprocessor,
which eliminates the need for fieldaddressing of the units. Each unit also
ships from the factory with a unit identification tag. (See “Location Identifier”
on page 23, for more information.)
Building automation system
Trane offers a state-of the art front-end
building automation system designed
to coordinate and monitor Trane equipment and controllers: Tracer Summit.
The Tracer Summit system allows the
user to monitor and/or change Tracer
ZN524:
• status, parameters, sensor data,
diagnostics, and internal variables;
and
• setpoints, operating modes, and out
puts.
Service tool
Trane also offers a service tool to work
in conjunction with the Tracer Summit
system or with peer-to-peer and standalone systems: the Rover service tool.
Communication to the Tracer ZN524, or
multiple controllers, can also be accomplished by using the ICS software service tool.
A personal computer running Rover
may be directly connected to a standalone Tracer ZN524; connected to the
communications jack in the Trane zone
sensor; or connected to a communicat-
ing unit’s Tracer ZN524
unit controller, to access
all of the units on a communicating link.
Rover allows the user to
interface with the Tracer
ZN524, but will not allow
any advanced control
(e.g. equipment scheduling or trending). To purchase a copy of the ICS
software service tool,
contact the BAS department at your local Trane
dealer.
Stand-Alone
In a stand-alone configuration, commands for operation are determined
based on input from the zone sensor,
humidity sensor, and field-mounted
timeclock (See Figure 6).
• Timeclock can be wired to the Tracer
ZN524 to index the unit between
occupied and unoccupied modes.
• A unit-mounted, analog, leaving
water temperature sensor is used to
initiate the boilerless control or the
optional waterside economizer
routines.
These sensors are required for proper
system operation and are provided as
standard on stand-alone units.
Typical water-source heat pump installation
Interoperability
Trane has lead the industry with
BACnet interoperability and Trane is
now expanding the realm of interoperable solutions by offering LonMark certified unit controllers. The Tracer ZN524
controller conforms to the LonMark
Space Comfort Controller profile. (See
“Appendix—Data Lists” on page 47, for
more information.) This allows the
ZN524 to be used as a unit controller
on other control systems that support
LonTalk and the SCC profile. Now building owners have more choices and
design engineers have more flexibility
to meet the challenges of building
automation.
Communication Configurations
Figure 6: Standard GEH (horizontal water-source
heat pump) with single control
10 CNT-SVX11A-EN
Specifications
Dimensions
Tracer ZN524 board and mounting
hardware:
• Height: 5.25 inches (133 mm.)
• Width: 5.50 inches (140 mm)
• Depth: 2.25 inches (57 mm)
Power Requirements
• 18 to 32 VAC (24 VAC nominal)
• 50 or 60 Hz
• 570 mA AC
Operating Environment
• 32° to 140°F (0× to 60°C)
• 5% to 95% relative humidity,
non-condensing
Storage Environment
• -40° to 185°F (-40° to 85°C)
• 5% to 95% relative humidity, noncondensing
Agency Listings
• UL and CUL 916 Energy Management
System
• Agency Compliance IEC 1000-4-2
(ESD), IEC 1000-4-4(EFT), IEC 1000-4-5
(Surge)
Installation & Wiring
Figure 7: Tracer ZN524 circuit board schematic
Installation & Wiring
CNT-SVX11A-EN 11
Binary input Pin Location Function Configuration Valid range
BI 1 J2 - 1 24 VAC Low evaporation temperature Normally open
J2 - 2 Input Normally closed
BI 2 J2 - 3 24 VAC Condensate overflow Normally open
J2 - 4 Input Normally closed
BI 3 J2 - 5 24 VAC Occupancy/Generic Normally open
J2 - 6 Input Normally closed
BI 4 J2 - 7 24 VAC Fan status or not used Normally open
J2 - 8 Input Normally closed
1. Trane Rover service tool uses the unit type to help determine and download the proper default binary input configuration.
Binary Inputs
Each binary input associates an input
signal of 0 VAC with open contact and
24 VAC with closed contacts.
Binary Outputs
Outputs are load side switching triacs.
The triac acts as a switch, either making
or breaking the circuit between the load
(valve, damper, contactor, relay) and
ground.
Table 1: Binary input summary for the J2 terminal board connections
1
Binary Pin Function Valid range Output Load Load
Output Location Rating Energized De-Energized
BOP-1 J1-1 Fan NA 12VA 1 VAC RMS 24 VAC RMS
BOP-2 J1-2 Reversing valve NA 12VA 1 VAC RMS 24 VAC RMS
BOP-3 J1-3 Electric heat or reheat NA 12VA 1 VAC RMS 24 VAC RMS
J1-4 (Key) NA 12VA 1 VAC RMS 24 VAC RMS
BOP-4 J1-5 Compressor 1 Normally open or 12VA 1 VAC RMS 24 VAC RMS
normally closed
2
BOP-5 J1-6 Compressor 2 NA 12VA 1 VAC RMS 24 VAC RMS
BOP-6 J1-9 Isolation valve 1 Normally open or 12VA 1 VAC RMS 24 VAC RMS
normally closed
2
BOP-7 J1-10 Isolation valve 2
4
NA 12VA 1 VAC RMS 24 VAC RMS
BOP-8 J1-11 Economizer valve NA 12VA 1 VAC RMS 24 VAC RMS
BOP-9 J1-12 Outdoor air damper NA 12VA 1 VAC RMS 24 VAC RMS
BOP-10
3
TB4-1/ Generic output NA 12VA 1 VAC RMS 24 VAC RMS
TB4-2
Table 2: Binary output summary
1
1. Trane Rover service tool uses the unit type to help determine and download the proper default binary output configuration.
2. The normally open/closed configuration item refers to the inactive state of the controller output.
3. BOP-10 is a generic output but requires a 24 VAC source for usage.
4. Typical factory installation has only one (1) ISO valve.
12 CNT-SVX11A-EN
Installation & Wiring
Description Terminals Function Range
Zone TB3-1 Space temperature input 5× to 122×F
(-15× to 50×C)
Ground TB3-2 Analog ground NA
Set TB3-3 Local setpoint input 40× to 115×F
(4.4× to 46.1×C)
Fan TB3-4 Fan switch input 4821 to 4919 V (Off)
2297 to 2342 V (Auto)
15137 to 16463 V (High)
Ground TB3-6 Analog ground NA
Analog Inputs
Table 3: Analog Inputs (Zone Sensor)
Analog input Terminal Function Range
AI 1 J3 - 1 Entering water temperature or -40 to 2120F (-400to 1000C)
J3 - 2 outside air temperature -40 to 2120F (-400to 1000C)
AI 2 J3 - 3 Discharge air temperature -40 to 212
0
F (-400to 1000C)
J3 - 4
AI 3 J3 - 5 Leaving water temperature -40 to 212
0
F (-400to 1000C)
J3 - 6
AI 4 J3 - 7 Universal 4-20mA input 4-20ma
J3 - 8 Humidity 0-100%
J3 - 9 CO
2
0 - 2000 ppm
Table 4: Analog Inputs with terminal connections
1,2
1. Trane Rover service tool uses the unit type to help determine and download the proper default analog input configuration.
2. Analog input 3 (AI 3) configured as generic temperature input does not affect unit operation. When configured, the TracerTMZN524 unit con-
troller communicates the generic temperature value to Rover or Tracer Summit and displays it as generic temperature.
CNT-SVX11A-EN 13
Installation & Wiring
Mounting
The Tracer ZN524 circuit board is located in the control box, which is mounted
behind the front panel of the watersource heat pump (See Figures 9 and
10 for more information). The sheet
metal mounting plate has raised
embosses to accept the mounting feet
on the circuit board. (See Figure 8: For
close-up of horseshoe embosses and
circuit board mounting feet.) This
design allows the Tracer ZN524 controller to be secured with a minimal
number of sheet metal screws
.
The mounting position on the vertical
water-source heat pump allows complete access to the Tracer ZN524 by
removing the front panel - six screws
total. (See Figure 9) Removing the
screws and panel allows access to the
components of the control board.
The mounting plate on both the horizontal and vertical water-source heat
pumps allow complete access to the
Tracer ZN524 by removing the front
panel - also six screws total. (See
Figure 10) Removing the screws and
panel allows access to the components
of the control board.
For additional convenience, quick connects and modular wire harnesses are
used on the control board and mounting plate. These quick connects help
facilitate ease of wiring devices (e.g.,
zone sensor) to the control board, and
helps add accessibility to major components.
WARNING
Hazardous Voltage!
Disconnect all electric power, including
remote disconnects before servicing.
Follow proper lockout/tagout procedures to ensure the power can not be
inadvertently energized. Failure to disconnect power before servicing could
result in death or serious injury.
Figure 8: A) Cut-away view of the
ZN524 control mounted on the control
box panel. B) Close-up of mounting
shoe on backside of control which slide
into the horseshoe brackets (C) on the
control panel.
Figure 9: Removing front panel of vertical unit to access control panel.
Figure 10: Removing front panel of
horizontal unit to access control panel.
A
C
B
14 CNT-SVX11A-EN
Installation & Wiring
Wiring
Live Electrical Components!
During installation, testing, servicing,
and troubleshooting of this product, it
may be necessary to work with live
electrical components. Have a qualified
licensed electrician or other individual
who has been properly trained in handling live electrical components perform these tasks. Failure to follow all
electrical safety precautions when
exposed to live electrical components
could result in death or serious injury.
Use Copper Conductors Only!
Unit terminals are not designed to
accept other types of conductors.
Failure to use copper conductors may
result in equipment damage.
Important! All wiring must comply
with state, local, and federal
guidelines. Contact the appropriate
local agency for further
information.
Important! Wires for temperature
sensors, communication lines, 24
VAC, and contact closure sensing
inputs should not be bundled with
or run near high voltage wiring.
• To prevent damage to the unit, refer to
the diagram provided on the unit’s
inside access panel for specific wiring
information. Most control components
are factory-wired. Zone sensors and
communication wiring is to be
installed by the contractor.
• Power wiring must be separated from
the Tracer ZN524 and all low voltage
wires. External input wires should be
run in separate conduits from high
voltage wires.
• Wires connected to pin headers
should be formed and routed so as to
cause minimum strain on the Tracer
ZN524 connector.
• A minimum of 1.5" clearance (from the
pin centerline) for wires up to 16 AWG
is recommended for bending and
forming wires.
• All sensor and input circuits are at or
near ground potential. Do not connect
any sensor or input circuit to an
external ground connection.
• A close-coupled ground connection is
required for the Tracer ZN524.
• Table 5: Tracer ZN524 Wiring
Requirements, shows Tracer ZN524
wire types and lengths.
Power
The Tracer ZN524 controller is powered
by 24 VAC. (See Table 5: “Tracer ZN524
wiring requirements”)A total of two 1/4inch quick-connect terminals are provided for 24 VAC connection to the board.
Figure 10: Power connections to the Tracer ZN524 unit controller
Application Wire Type Length
Contact 18 AWG Up to
Closure 1000 ft.
24 VAC 16-22 AWG Up to
1000 ft.
Zone 16-22 AWG Up to
Sensor 200 ft.
Communications Belden 8760 Up to
or 5000 ft.
equivalent
ZN524
WARNING
CAUTION
Table 5: Tracer ZN524 wiring
requirements
CNT-SVX11A-EN 15
Installation & Wiring
Installing the Wall-Mounted
Zone Sensor (Optional)
Zone sensor location is an important
element of effective room control and
comfort.
The best sensor location is typically on
a wall, remote from the HVAC unit.
Readings at this location assure that the
desired setpoint is achieved across the
space, not just near the unit itself.
Note: It may be necessary to
subdivide the zone with multiple
units to ensure adequate control
and comfort throughout the space.
The following are typical areas where
the zone sensor should not be
mounted:
• Near drafts or “dead spots” (e.g.,
behind doors or corners);
• Near hot or cold air ducts;
• Near radiant heat (e.g., heat emitted
from appliances or the sun);
• Near concealed pipes or chimneys;
• On outside walls or other nonconditioned surfaces; or
• In air flows from adjacent zones or
other units.
The communications link is not connected in the factory. Communications
could be wired to the wall-mounted
sensor if desired.
Figure 11: Proper zone sensor placement
16 CNT-SVX11A-EN
Installation & Wiring
Zone Sensor Features
Fan Switch (Optional)
The zone sensor fan switch provides
the controller with an occupied (and
occupied standby) fan request signal of
off or auto. If the fan control request is
communicated to the controller, the
controller ignores the hardwired fan
switch input and uses the communicated value. The zone sensor fan switch
signal can be enabled or disabled
through configuration in the ZN524
controller.
ON or CANCEL Buttons
Momentarily pressing the on button
during unoccupied mode places the
controller in occupied bypass mode for
120 minutes. You can adjust the number
of minutes in the unit controller configuration using Trane’s service tool,
Rover. The controller remains in occupied standby mode until the override
timer expires or until the cancel button
is pressed.
Communication Jack
Use the RJ-11 communication jack as
the connection point from Rover to the
communication link (when the communication jack is wired to the communication link at the controller). By accessing the communication jack via Rover,
entrance to all controllers on the link
may be gained.
Table 6: Zone Sensor Options
Part number:
X13510628010
Description:
• Space temperature
(0.2 C resolution)
• Internal setpoint
• Communication jack
• Vertical case with Trane logo
Part number:
X13510606010
Description:
• Space temperature
(0.2 C resolution)
• External setpoint
• Communication jack
• Vertical case with Trane logo
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