Trane VariTrac Installation and Maintenance Manual
Installation Manual
VariTrac
™
Central Control Panel
June 2002 VAV-SVN03A-EN
VariTrac Central Control Panel Installation Manual
This manual and the information in it are the property of American Standard
Inc. and shall not be used or reproduced in whole or in part, except as
intended, without the written permission of American Standard Inc. Since
Trane has a policy of continuous product improvement, it reserves the right
to change design and specification without notice.
Use of the software contained in this package is provided under a software
license agreement. Unauthorized use of the software or related materials
discussed in this manual can result in civil damages and criminal penalties.
The terms of this license are included with the compact disk. Please read
them thoroughly.
Trane has tested the system described in this manual. However, Trane does
not guarantee that the system contains no errors.
Trane reserves the right to revise this publication at any time and to make
changes to its content without obligation to notify any person of such
revision or change.
Trane may have patents or pending patent applications covering items in
this publication. By providing this document, Trane does not imply giving
license to these patents.
The following are trademarks or registered trademarks of Trane: Reliatel,
Tracker, Trane, VariTrac, VariTrane, and Voyager.
VAV-SVN03A-EN
Printed in the U.S.A.
© 2002 American Standard Inc. All rights reserved.
Contents
About This Manual ............................................ 1
Contents .............................................................................................................. 1
Compliance Information .............................................................................. 1
Specifications ............................................................................................... 1
VariTrac Changeover Bypass System ......................................................... 1
Overview ................................................................................................ 1
Getting Started ...................................................................................... 1
Installing and Configuring the System ................................................ 1
Troubleshooting .................................................................................... 1
Delivered VAV System ................................................................................. 1
Overview ................................................................................................ 1
Getting Started ...................................................................................... 1
Installing and Configuring the System ................................................ 1
Naming Conventions ......................................................................................... 2
Cautionary Statements ...................................................................................... 2
Related Literature ............................................................................................... 2
FCC Information ............................................... 3
VariTrac and Delivered VAV Radio and Television Interference ........................ 3
VariTrac Changeover-Bypass System ................ 5
Overview ............................................................................................................. 5
Central Control Panel ................................................................................... 5
Unit Control Module (UCM) ........................................................................ 5
VariTrac Damper........................................................................................... 5
Communicating Sensor/Bypass Damper Control ...................................... 6
VariTrac Bypass Damper ....................................................................... 6
Communicating Sensor/Bypass Control .............................................. 6
Auxiliary Temperature Sensor ..................................................................... 6
Zone Temperature Sensors .......................................................................... 6
CO2 Sensor ................................................................................................... 7
Occupancy Sensor ....................................................................................... 7
Operator Display (optional) ......................................................................... 7
Service Model Number Description ........................................................... 7
Specifications ................................................... 9
VariTrac Central Control Panel ........................................................................... 9
Operator Display .............................................................................................. 10
VAV-SVN03A-EN i
UCM Damper .................................................................................................... 10
Communicating Sensor/Bypass Control Assembly ........................................ 11
Relay Board Binary Outputs ............................................................................. 11
Wire Specifications ........................................................................................... 11
Getting Started ............................................... 13
Unpack and Inspect the Components ............................................................. 13
Mount the Wiring Base ..................................................................................... 14
Mounting Requirements............................................................................ 14
Location................................................................................................ 14
Operating Environment....................................................................... 14
Clearances ............................................................................................ 14
Secure Termination Module Wall ............................................................... 15
Secure Termination Module to Conduit Box ............................................. 16
Install VariTrac CCP Relay Board ............................................................... 16
Wire AC Power .................................................................................................. 17
CCP Field Wiring ......................................................................................... 17
AC Power Wiring .................................................................................. 18
AC Power Checkout ............................................................................. 18
Binary Input Wiring .......................................................................................... 18
Priority Shutdown Input Wiring .......................................................... 18
Occupied/Unoccupied Input Wiring ................................................... 19
Output Wiring ................................................................................................... 19
Install the Bypass Dampers and Communicating
Sensor/Bypass Control Assembly ................................................................... 20
Install Bypass Dampers ............................................................................. 20
Bypass Damper Wiring .............................................................................. 21
Mount the Communicating Sensor/Bypass Control ................................ 21
Connect the Communicating Sensor/Bypass Control Wiring ................. 22
Install the VariTrac Dampers ............................................................................ 23
Connect UCM Wiring ................................................................................. 24
Set the UCM DIP Switches ........................................................................ 25
Slaved Dampers ............................................................................................... 26
Install the Zone Temperature Sensors ............................................................. 28
Location ...................................................................................................... 28
Mounting Standard and Digital Zone Temperature Sensors ................... 29
Wall Mount........................................................................................... 29
Junction Box Mount ............................................................................ 29
Zone Temperature Sensor Wiring .............................................................. 30
Communication Link Wiring ............................................................................ 32
Mount Main Module .................................................................................. 36
Install Operator Display (optional) ............................................................ 37
Connecting Modem Devices ..................................................................... 38
VAV-SVN03A-ENii
Connecting PC with VariTrac Software to CCP ......................................... 39
Installation Checklist...................................... 41
Shipment .................................................................................................... 41
Unit Location .............................................................................................. 41
AC Power Wiring ........................................................................................ 41
Communicating Sensor/Bypass Assembly .............................................. 41
Input Wiring ................................................................................................ 41
Output Wiring ............................................................................................. 41
VariTrac Dampers ....................................................................................... 42
Zone Temperature Sensors ........................................................................ 42
UCM Wiring ................................................................................................ 42
Communication Link Wiring ...................................................................... 42
System Start-Up and Checkout ...................... 43
Pre-power-Up Checkout ................................................................................... 43
Central Control Panel ................................................................................. 43
UCM ............................................................................................................ 43
Occupied Mode ................................................................................... 44
Unoccupied Mode ............................................................................... 44
Powering Down the System ...................................................................... 44
UCM LEDs .................................................................................................. 44
Green LED ............................................................................................ 45
Yellow LED ........................................................................................... 45
Tests and Troubleshooting .............................. 47
Displayed Failures ............................................................................................ 47
Static Sensor Calibration Failure............................................................... 47
Discharge Air Temperature Sensor Failure ............................................... 47
Communication Failure ............................................................................. 47
Zone Sensor Failure ................................................................................... 48
Zone Setpoint Failure ................................................................................ 48
Auxiliary Sensor Failure ............................................................................ 48
Static Pressure Sensor Troubleshooting ................................................... 48
Zone, Auxiliary and System Temperature Sensor Checkout ................... 48
UCM Local Heat Checkout ......................................................................... 50
Central Control Panel Input/Output Test .......................................................... 50
Binary Input Tests ....................................................................................... 50
Communicating Sensor/Bypass Control Test ........................................... 50
Supply Air Temperature Input Test ...................................................... 50
Static Pressure Sensor Input Test ....................................................... 51
Binary Output Test ............................................................................... 51
System Troubleshooting .................................................................................. 51
VAV-SVN03A-EN iii
Delivered VAV System .................................... 53
Overview ........................................................................................................... 53
What is Delivered VAV? ............................................................................. 53
What Delivered VAV is Not ........................................................................ 53
Central Control Panel ................................................................................. 55
Unit Control Module (UCM) ...................................................................... 55
VariTrane VAV Terminal Units .................................................................... 55
VariTrane VAV Terminal Unit Types ............................................................ 55
Single Duct ........................................................................................... 55
Parallel Fan-Powered ........................................................................... 55
Series Fan-Powered ............................................................................. 55
Auxiliary Temperature Sensor ............................................................. 56
Zone Temperature Sensors ................................................................. 56
CO
Sensor ........................................................................................... 56
2
Occupancy Sensor............................................................................... 56
Operator Display.................................................................................. 56
Getting Started ............................................... 57
Installing the Central Control Panel................................................................. 57
Install VariTrane VAV Terminal Units ................................................................ 57
Connect UCM Wiring ................................................................................. 57
Set UCM DIP Switches ............................................................................... 57
Installing Zone Temperature Sensors ....................................................... 57
Communications Link Wiring .................................................................... 57
Installation Checklist...................................... 63
Shipment .................................................................................................... 63
Unit Location .............................................................................................. 63
AC Power Wiring ........................................................................................ 63
Input Wiring ................................................................................................ 63
VariTrane Terminal Units ............................................................................ 63
Zone Temperature Sensors ........................................................................ 63
UCM Wiring ................................................................................................ 63
Communication Link Wiring ...................................................................... 64
Completing Central Control Panel Assembly ................................................. 64
Mount Main Module .................................................................................. 64
Install Operator Display ............................................................................. 64
Connecting Modem Devices ..................................................................... 64
VAV-SVN03A-ENiv
About This Manual
Contents
This manual describes the steps required to install and configure VariTrac
Changeover Bypass Zoning and Delivered VAV Systems. Sections in this
manual are highlighted below:
Compliance Information
Information about FCC approval and possible radio and telephone interference, and the CE compliance statement.
Specifications
Technical specifications for VariTrac Central Control Panel unit and system
components.
VariTrac Changeover Bypass System
Overview
A brief description of a typical VariTrac changeover bypass system.
Getting Started
Pre-installation and setup information.
Installing and Configuring the System
Installation and configuration information, including an installation checklist.
™
Troubleshooting
General troubleshooting guidelines for common problems.
Delivered VAV System
Overview
A brief description of a typical delivered VAV system.
Getting Started
Pre-installation and setup information.
Installing and Configuring the System
Installation and configuration information, including an installation checklist.
VAV-SVN03A-EN 1
About This Manual
Naming Conventions
The following is a list of naming conventions used in this manual:
• CCP: Refers to the system Central Control Panel
• VariTrac: Refers to the CCP used in a pressure dependent bypass zoning
system
• Delivered VAV: Refers to the CCP used with a Commercial Voyager VAV
rooftop unit and VariTrane pressure independent VAV boxes
• VAV: Variable air volume
Cautionary Statements
The following cautionary statements signal procedures or conditions that
require particular attention.
WARNING
Indicates a potentially hazardous situation, which, if not avoided, could
result in serious injury or death.
CAUTION
Indicates a potentially hazardous situation, which, if not avoided, may
result in minor or moderate injury.
CAUTION
Indicates a situation in which property-damage-only accidents could occur.
It is also used to alert against unsafe practices.
IMPORTANT
Alerts installer, servicer, or operator to potential actions that could cause
the product or system to operate improperly, but will not likely result in
potential for damage.
Related Literature
VAV-SVX01B-EN: UCM 4.0 and Wireless VAV Communication
VAV-SLB006-EN: Zone Occupancy Sensor
VAV-SLB007-EN: Digital Display Zone Sensor
VAV-SLB008-EN: Zone and Duct CO2 Sensor
VAV-SVP01A-EN: VariTrac Operator’s Guide
VAV-SVN03A-EN2
FCC Information
VariTrac and Delivered VAV Radio and
Television Interference
VariTrac and Delivered VAV generate, use, and can radiate radio frequency
energy. If not installed and used in accordance with the instruction manual,
interference to radio and television reception may occur. VariTrac and
Delivered VAV are tested and comply with the limits for Class A computing
devices in accordance with the specifications in Subpart J of Part 15 of FCC
rules, to provide reasonable protection against such interference in a
commercial installation.
There is no guarantee that interference will not occur in a particular
installation. If interference does occur, consult a radio or television
technician for suggestions to correct the problem. Also, the booklet
Identify and Resolve Radio-TV Interference Problems
U.S. Government Printing Office, Washington, DC 20402.
Order stock #004-000-00345-4.
is available from the
How to
VAV-SVN03A-EN 3
FCC Information
The manufacturer hereby declares that the product:
Conforms to the following standards or other normative documents:
'HFODUDWLRQRI&RQIRUPLW\
Manufacturer’s Name:
Manufacturer’s Address:
Product Name:
Product Number:
Product Option:
Electromagnetic Emission:
(by Council Directive 89/336/EEC)
Electromagnetic Immunity:
Trane
4833 White Bear Parkway
Saint Paul, Minnesota 55110
USA
VariTrac CCP Controller
X13650940010; X13650942010
Operator Display
EN 50081-1:1998
Radiated EN55022: 1998 Class B limit
Conducted EN55022: 1998 Class B limit
EN61326-1:1997 +A1: 1998
EN61000-4-2 ±4 kV contact discharge
±8 kV air discharge
EN61000-4-3 3 V/m
EN61000-4-4 ±1 kV
EN61000-4-5 ±1 kV
EN61000-4-6 3 V
EN61000-4-8 30 A/m
EN61000-4-11 1 cycle/100%
When and where issued
Electromagnetic Emission : 4/3/2001 Bounheng Saycocie
Electromagnetic Immunity: 4/17/2001 Design/Compliance Engineer
Saint Paul, Minnesota USA
Mark of Compliance European Contact
Societe Trane (Epinal, France)
1, rue des Ameriques, B.P. 6
F-88191 Golbey Cedex, France
Phone: (33) 329.31.73.00
Fax: (33) 329.81.24.98
This document validates CE conformity of the VariTrac CCP controller.
VAV-SVN03A-EN4
VariTrac Changeover-Bypass
System
Overview
VariTrac Changeover-bypass VAV is a comfort system solution designed for
light commercial applications. As the name implies, these systems deliver a
varying volume of air to multiple zones, each with its own thermostat, while
still utilizing a unitary machine with a constant volume fan. Changeoverbypass VAV combines the comfort benefits of VAV with the cost effectiveness and simplicity of packaged unitary equipment.
Central Control Panel
The VariTrac Central Control Panel is the central source of communications
and decision making between the individual zones and the air conditioning
unit. Connections to the central control panel are:
• 24 Vac power
• binary inputs for an occupied/unoccupied signal and external priority
shutdown signal (optional)
• ICS communication bus to the Trane building automation system (optional)
• UCM communication bus to the zone dampers and communicating
sensor/bypass damper control and Trane Voyager™/Reliatel™ rooftop unit
• binary outputs to heating, cooling, and fan of non-Voyager or Reliatel
rooftop units
Unit Control Module (UCM)
A unit control module is mounted to each individual zone damper. Inputs
and outputs consist of the twisted shielded pair communication link, zone
temperature sensor, optional CO2 and occupancy sensors, 24 Vac power,
damper motor control, and local heat outputs. Local heat may be duct or
space mounted, and can be staged electric, pulse-width modulating electric,
and modulating or staged two-position hot water.
VariTrac Damper
Each VariTrac damper consists of an integrated 24 Vac actuator and control
box that encloses the UCM circuit board. The damper is designed to operate
in static pressures up to 1.75 inches wg.
VariTrac dampers are referred to by their dimensions:
• round damper sizes are 6, 8, 10, 12, 14, and 16 inches. The dampers consists of an 18 gage galvanized steel frame with a round damper blade
assembly.
VAV-SVN03A-EN 5
VariTrac Changeover-Bypass System
• rectangular damper sizes are 8 x 12, 8 x 14, 8 x 16, 10 x 16, 10 x 20, and
Communicating Sensor/Bypass Damper Control
The communicating sensor/bypass damper assembly is a bypass damper
and communicating sensor/bypass control that resides on the same bus as
the VariTrac dampers and Voyager/Reliatel rooftop unit.
VariTrac Bypass Damper
Bypass dampers are non-communicating VariTrac dampers which include an
integrated actuator with a pre-wired interconnect cable that plugs into the
communicating sensor/bypass control.
• round bypass damper sizes are 6, 8, 10, and 12 inches. The damper con-
• rectangular bypass damper sizes are 14 x 12, 16 x 16, 20 x 20, and 30 x 20
14 x 16 inches. The damper consists of a 16 gage galvanized steel frame
and opposed blade damper assembly.
sists of an 18 gage galvanized steel frame with a round damper blade
assembly. The round bypass damper operates in duct static pressures up
to 1.75 inches wg.
inches. The damper consists of a 13 gage galvanized steel frame and
opposed blade damper assembly. The rectangular bypass damper operates in duct static pressures up to 2.00 inches wg.
Communicating Sensor/Bypass Control
The Communicating Sensor/Bypass Control is composed of an integrated
UCM board, static pressure, and discharge air temperature sensors. It
directly controls the bypass damper and communicates duct conditions to
the central control panel.
The static pressure sensor measures duct static pressure and positions the
bypass damper(s) to maintain the static pressure setpoint.
The discharge air temperature sensor allows the CCP to determine the heat/
cool action of each individual UCM and cycles the heating and cooling
stages to maintain the discharge air temperature. Discharge air temperature
setpoints are also edited through the operator display or PC software.
Auxiliary Temperature Sensor
The auxiliary temperature sensor allows the operator to monitor air
temperature leaving a reheat device or measure duct temperature for
automatic operation of a standalone UCM.
Zone Temperature Sensors
Five zone temperature sensor configurations are available:
• sensor only
• sensor with adjustable setpoint and communications jack
• sensor with night setback override button, cancel button, and communica-
tions jack
• sensor with adjustable setpoint, night setback override button, cancel
button, and communications jack
VAV-SVN03A-EN6
VA DA06 BYP 1
ProductType
Damper Size
VA = VariTrac Product Families
D = Damper
R = Rectangular Damper
A = Development Sequence
DA06 = 6” Damper
DA08 = 8” Damper
DA10 = 10” Damper
DA12 = 12” Damper
DA14 = 14” Damper
DA16 = 16” Damper
RA0812 = 8” x 12” Zone Damper
RA0814 = 8” x 14” Zone Damper
RA0816 = 8” x 16” Zone Damper
RA1016 = 10” x 16” Zone Damper
RA1020 = 10” x 20” Zone Damper
RA1418 = 14” x 18” Zone Damper
RA1412 = 14” x 12” Bypass Damper
RA1616 = 16” x 16” Bypass Damper
RA2020 = 20” x 20” Bypass Damper
RA3020 = 30” x 20” Bypass Damper
Inventory Number
Damper Control
BYPS = Bypass Control
BYR = Rectangular Bypass Control
CHGR = Changeover Control
ELEC = 3 Stage, Primary Heat Disabled Control
NCHW = 1 Stage, Primary Heat Enabled
CO2 Sensor
• sensor with digital display, adjustable setpoint, night setpoint override
button, cancel button, and communications jack
CO2 Sensor
A CO2 sensor may be connected to the UCM damper control to sense CO
levels in the space. This signal is communicated to the CCP for demand
ventilation calculation and control.
2
Occupancy Sensor
A normally open occupancy sensor contact may be connected to the UCM
damper control binary input to indicate zone occupancy.
Operator Display (optional)
A 1/4 VGA monochrome LCD touch screen display is available for the CCP.
This display provides setup, diagnostic, and seven-day scheduling functions
to the system.
Service Model Number Description
Service model numbers determine product characteristics and are used
when ordering replacement parts. Each digit signifies product characteristics. See Figure 1.
Figure 1: Service Model Number Description
VAV-SVN03A-EN 7
VariTrac Changeover-Bypass System
Figure 2: VariTrac Changeover Bypass System Configuration
VariTrac
Zone Damper
Voyager or
Reliatel TCI-3
Bypass Damper
(w/connecting cable assembly)
Zone
Sensor
Communications Link (2 cond, Level 4 comm wire)
24 Vac
Sensor wiring
Legend
Communicating
Sensor/Bypass
Control Assembly
24 Vac
Transformer
VariTrac Central
Control Panel
VAV-SVN03A-EN8
Specifications
VariTrac Central Control Panel
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Specifications
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VAV-SVN03A-EN10
Communicating Sensor/Bypass Control Assembly
Communicating Sensor/Bypass Control
Assembly
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Relay Board Binary Outputs
Voltage provided: 24 Vac from air conditioning unit
Current: 10 VA maximum
Wire Specifications
Shielded Level 4 communication wire is now recommended for all communication link wiring on the new VariTrac CCP. This is the same wire which is
recommended for the Tracker Version 10 Comm5 communication link.
The term “Level 4” is used to specify a particular performance of communication wire and is normally associated with LonTalk™. Level 4 wire is different from Category IV (four) wire and Category V (five) wire. The specification
information for Level 4 wire can be found in the “LonWorks™ FTT-10A Free
Topology Transcei ver User’s Guide” at www.echelon.com.
Shielded Level 4 communication wire can be purchased from two qualified
suppliers: Windy City Wire and Connect-Air.
VAV-SVN03A-EN 11
Specifications
Table 1: Communication Link Wire Specifications
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VAV-SVN03A-EN12
Getting Started
Familiarize yourself with the system components and preview the
installation procedures before installing and configuring the VariTrac
system.
Installation and configuring procedures appear in suggested order of
performance:
• Unpack and inspect the components
• Mount the wiring base
• Wire AC power
• Binary input wiring
• Output wiring
• Install communicating sensor/bypass damper control
• Install bypass damper(s) and connect to communicating sensor/bypass
control assembly
• Install VariTrac dampers
• Connect UCM wiring
• Set UCM DIP switches
• Install slaved dampers (if used)
• Install zone temperature sensors
• Communication link wiring
• Mount main module
• Install operator display (optional)
• Connecting modem devices
IMPORTANT
The CCP is designed to work with UCM III and IV VariTrac damper and
VariTrane VAV controllers produced beginning January 1995. If any other
dampers are used (especially on a retrofit job), please consult the factory
to confirm VariTrac Central Control Panel compatibility prior to installation.
Unpack and Inspect the Components
Inspect components for damage. Match each component to the packing list
to ensure that nothing was lost during shipment. Make sure that the literature is not lost or discarded with the packing material. Visually inspect the
central control panel for damage. All components are thoroughly inspected
before leaving the factory. Any claims for damage incurred in shipping must
be filed with the carrier.
VAV-SVN03A-EN 13
Getting Started
Mount the Wiring Base
Figure 3: Termination module conduit access and mounting holes
Conduit connector
Holes for mounting on a 2 in. x 4 in.
conduit box horizontally
(left and right)
Two holes for mounting on a wall
(one on each side)
Conduit access
(three places)
Termination board
Holes for mounting on a 2 in. x 4 in.
Holes for mounting on a
4 in. x 4 in. conduit box
(four corners)
Jamb nut
(attaches to
conduit connector)
conduit box vertically
(top and bottom)
Mounting Requirements
Location
The VariTrac Central Control Panel should be mounted at a convenient level
and located where it will be easily accessible. If possible, locate the CCP
near the controlled equipment to reduce wiring cost.
Operating Environment
The VariTrac Central Control Panel is designed for indoor use only. It should
be located in a dust-free and corrosive-free environment, and within a range
of 32° to 120°F, and 10 to 90 percent humidity (non-condensing).
Clearances
Mount the VariTrac Central Control Panel on any vertical flat surface. The CCP
is approximately 8.75 inches high, 10.25 inches wide and 2.75 inches deep.
VAV-SVN03A-EN14
Secure Termination Module to Wall
The VariTrac Central Control Panel should be easily accessible for making
wiring connections and for servicing. Provide two inches of clearance on the
left and right sides, and sufficient clearance above the unit to make conduit
connections. Sufficient space should be available in front of the unit to
making wiring connections and perform maintenance.
Figure 4: Dimensions for VariTrac Central Control Panel Components
Top view
8.75 in.
(22.38 cm)
10.25 in.
(26.04 cm)
Front view
2.75 in.
(6.99 cm)
Side view
Bottom view
Secure Termination Module to Wall
1 Mark the location of the two mounting holes on the wall.
2 Set the termination module aside and drill mounting holes.
3 Secure the termination module to the wall with the supplied hardware
(#10 x 1 in. screw with plastic anchor).
VAV-SVN03A-EN 15
Getting Started
Secure Termination Module to Conduit Box
1 Remove the screws from the conduit box.
2 Line up the conduit box screw holes on the termination module (Figure 3)
with the screw holes on the conduit box.
3 Install the screws.
NOTE: When mounting the termination module to a 4 in. x 4 in. conduit box,
remove the plastic cover over the box for easier access. Do not attempt to break
away excess plastic. Use a hack saw blade and carefully cut away the plastic.
Install VariTrac CCP Relay Board
1 Separate the main module and front panel from the termination module.
2 Remove the relay board from its packaging.
3 Orient the relay board so that its 20-pin socket connector faces left (see
Figure 5).
4 Slide the left edge of the board underneath the catches on the left side.
5 Rotate the board to the catches on the right side.
6 Snap the board into place by pressing on the terminal block or on the
right side of the board.
Figure 5: Installing Optional Relay Board
VAV-SVN03A-EN16
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