Trane WSHP-PRC001-EN User Manual

High Efficiency Horizontal and Vertical Water-Source Comfort System

Axiom 1/2 - 5 Tons — 60 HZ— Model GEH/GEV

March 2005

WSHP-PRC001-EN

Introduction

Imagine a full range of comfort utilizing efficiency, sound attenuation, integrated controls, and superior maintenance accessibility... Trane imagined it, and designed an advanced mechanical system. Introducing models GEH and GEV water source comfort solutions.

Model GEH (pictured below) is a ceiling hung product that provides a sleek, innovative shape, along with convertibility of the supply-air and the return-air arrangement; serviceability to maintenance components; indoor air quality standards; sound attenuation; and best of all, higher efficiencies with certified ARI-ISO 13256-1 performance and ASHRAE 90.1 standards.

Trane’s new design incorporates system advantages such as:

Maximum return-air and supply-air flexibility

Superior maintenance

accessibility

Dual-sloped, plastic drain pan

Multi-speed motor

Insulated enclosure for quiet

unit design

Integrated controls

Orifice ring motor mounting

device as standard for ease of motor service

High and low pressure

safeties as standard

Internal air-to-refrigerant coil

(horizontal design)

Introduction 2

Features and Benefits 4

Options 4

Controls 14

Application Considerations 22

Selection Procedures 31

How to Select by Computer 31

Model Number Description 32

General Data 34

Performance Data 37

Cool and Heat Performance 38

Correction Factors 62

Electrical Performance 63

Fan Performance 66

Waterside Economizer Performance 68

Anti-Freeze Correction Factors 69

Controls 70

Wiring 70

Dimensional Data 74

Accessories 86

Thermostats 86

Options 88

Mechanical Specifications 90

WSHP-PRC001-EN 3

Features and Benefits

Design Advantages

The horizontal and vertical configuratios range in capacities from 1/2 to 5 tons.

The innovative designs offers superior field flexibility at the jobsite along with service accessibility.

Model GEH Cabinet

The GEH cabinet design includes a modular platform that utilizes similar parts and assemblies throughout the product line. It is constructed of heavy gauge (non-painted) galvanized metal for maximum durability and corrosive resistive exterior.

The cabinet front allows service access for the controls and refrigeration circuitry. Water-in/out connection and high/low voltage hook-up is accomplished at the 45-degree corners on the front-side of the equipment. The unit offers six product variations of return-air and supply-air combinations which may be order-specific or job-site modified. See Figure 1 component platform location.

Model GEV Cabinet

The vertical design, model GEV includes a 3 1/3-ton configuration physically sized for condominium installations.

The cabinet design contains a modular platform utilizing similar parts and assemblies to the horizontal to provide a repetitious look and feel for installation and maintenance personnel. It is constructed of heavy gauge (non-painted) galvanized metal for maximum durability and corrosive resistive exterior.

The cabinet front allows service access for the controls and refrigeration circuitry. Water-in/out connection, drain connection, and high/low voltage hook-up is accomplished at the 45-degree chamfered corners on the front-side of the equipment. The vertical design offers four product variations of return-air and supply-air combinations.

The GEV model’s supply air arrangement may be field converted through a service kit to aid in stocking of a single unit variation. See Figure 2 for component platform location.

Figure 1: Component platform location

Figure 2: Component platform location

4 WSHP-PRC001-EN

Features and Benefits

FRONT

UNIT

FRONT

UNIT

FRONT

Figure 3: Airflow combinations of GEH 1/2 through 5-tons

UNIT

FRONT

UNIT

FRONT

Supply/Return Air Combinations

The GEH model configuration may be built to order or modified on-site to meet unique installation requirements. The six combinations include:

1 Left return-air with left supply-air

combination

2 Left return-air with rear supply-air

combination

3 Left return-air with right supply-air

combination

4 Right return-air with left supply-air

combination

5 Right return-air with rear

supply-air combination

6 Right return-air with right

supply-air combination

UNIT

FRONT

UNIT

FRONT

UNIT

FRONT

UNIT

FRONT

Figure 4: Airflow combinations of GEV 1/2 through 5-ton

See Figure 3 for the six field convertible combinations.

GEV Flexibility

The GEV model is also capable of on-site modifications. With the vertical configuration, the supply-air is easily converted from a top supply-air to a back supply-air with a service retrofit kit. The return-air option is order specific. The four combinations include:

1 Right return-air with top supply-air

combination

2 Right return-air with back supply-air

combination

3 Left return-air with top supply -air

combination

4 Left return-air with back supply-air

combination

See Figure 4 for the four supply-air/return-air combinations.

WSHP-PRC001-EN 5

Features and Benefits

Hanging Device

The hanging bracket resides in the chamfered corner of the horizontal 1/2 to 5 ton equipment. This partially-concealed bracket design eliminates added height, width, or length to the product. The brackets are factory mounted to shorten job installation requirements.

The structural integrity of the design helps assure no bracket deflection or unit bowing from the unit’s weight.

Field return-air hook-up and filter maintenance are more simplistic. Isolation for the hanging bracket is provided with a neoprene rubber grommet design. This isolation device helps prevent sound vibration from reaching the structural support members of the building during compressor start and stop. See Figure 5 for isolation device.

Drain Pan

The unit drain pan is composed of plastic, corrosive resistive material. The pan is positively sloped to comply with ASHRAE 62 for (IAQ) indoor air quality conformity. Access to the drain pan is provided through two access panels for cleaning purposes. See Figure 6 for plastic drain pan.

Cabinet Insulation

The cabinet insulation design meets UL 181 requirements. The air stream surface of the insulation is fabricated of a non-biodegradable source.

Refrigeration Piping

The unit’s copper tubing is created from a 99% pure copper formation that conforms to the American Society of Testing (ASTM) B743 for seamless, light-annealed processing. The unit’s copper refrigeration system is designed to be free from contaminants and conditions such as drilling fragments, dirt, or oil. This excludes the possibility of these contaminants from damaging the compressor motor.

Compressor

The unit’s design includes a wide variety of compressor motors to accommodate dedicated voltages and tonnage sizes. The 1/2 ton through 1 1/2 ton products embody a rotary compressor design, where as unit sizes ranging from 2 ton through 4 ton include a reciprocating compressor style, while the 5 ton unit contains a scroll compressor. These different styles allow Trane to provide the voltage variations along with noise reduction required in today’s applications. See Figure 7 for reciprocating compressor.

Schrader Connections

The connections for the low and high side of the refrigeration system are located directly beside the control box at the front, service access panel. See Figure 8 for schrader connection lo- tion.

Figure 5: Hanging bracket design

Figure 6: Plastic drain pan

Figure 7: Reciprocating compressor

Figure 8: Schrader connections

6 WSHP-PRC001-EN

Features and Benefits

Figure 9: Coaxial water coil

Figure 10: Water connection device

Figure 11: Thermal expansion valve

Co-axial Water-to-Refrigerant Coil

The unit’s internal heat exchanging water coil is engineered for maximum heat transfer.

The copper or cupro-nickel seamless tubing is a tube within a tube design. The inner-water tube contains a deep fluted curve to enhance heat transfer and minimize fouling and scaling. It is available in either copper or cupro-nickel (selectable option) coil.The outer refrigerant gas tube is made from steel material. The coil is leak tested to assure there is no cross leakage between the water tube and the refrigerant gas (steel tube) coil. Co-ax-

ial heat exchangers are more tolerant to freeze rupture. See Figure 9 for

co-axial water coil.

Compressor and Co-axial Coil Isolation

Vibration isolation of the compressor and co-axial water coil is accomplished by increasing the rigidity and stiffness at the base. The platform provides double isolation to the compressor and single isolation to the co-axial water coil for additional attenuation during compressor start and stop.

Water Connections

The water-in/water-out connections to the co-axial water coil are located on the right-hand chamfered corner of the unit. The fittings are mounted flush to the chamfered wall to help limit shipping damage.

The water connection devices are constructed of copper or bronze material and include a National Female Pipe Thread (NFPT) junction. The connections are attached to the unit’s chamfer corner to alleviate the need for a back-up wrench during installation. See Figure 10 for water connection device.

lows the unit to operate with an entering fluid temperature from 25 F to 110 F, and entering air temperatures from 40 F to 90 F. The valve is designed to meter refrigerant flow through the circuitry to achieve desired heating or cooling.

The expansion valve device allows the exact amount of refrigerant required to meet the coil load demands. This precise metering by the TXV increases the efficiency of the unit. See Figure 11 for thermal expansion valve.

Reversing Valve

A system reversing valve (4-way valve) is included with all heating/ cooling units. This valve is piped to be energized in the cooling mode to allow the system to provide heat if valve failure were to occur. Once the valve is energized for cooling, it will remain energized until the control system is turned to the OFF position, or a heating cycle is initiated.

Units with the cooling only option will not receive a reversing valve. See Fig- ure 12 for reversing valve.

Expansion Valve

All Trane water-source systems include an expansion valve flow metering device.

Figure 12: Reversing valve

WSHP-PRC001-EN 7

This thermal expansion valve (TXV) al-

Features and Benefits

Blower Motor

The supply-air (blower) motor is a multi-speed motor with internal thermal overload protection. The motor bearings are permanently lubricated and sealed. Standard motors are rated from .20 ESP. Optional high static motors are rated from .40 to 1.40 ESP. All motors are factory wired to the option selected. A high, medium, and low speed tap is provided for field customization on most voltages. The speed tap modification can be made in the control box of the unit. See Figure 13 for blower motor.

Note: The 380, 415, 460 and 575 volt designs are provided in a dual or three-speed version only. See fan performance section for factory ratings (Page 66).

Serviceability to the motor is made through either of the two air-side access doors for the horizontal configuration, and through one air-side access door on vertical configuration. The motor and blower wheel are removable by an orifice ring mounted to the fan housing.

Blower Housing

The blower housing is constructed of non-corrosive galvanized steel. A factory-mounted orifice ring is provided for ease of motor serviceability on the 1/2 through 5-ton direct drive units. All air-side panels are interchangeable with one another for ease of field convertibility of the supply-air on the GEH model.

Air-Side Filter

The air-side filter incorporates a 1-inch thick (nominal) or 2-inch thick (nominal) disposable fiberglass option. These filters include an average synthetic dust weight arrestance of approximately 75%. This dust holding capability includes a colorless, odorless adhesive to retain dirt particles within the filter media after fiber contact. See Figure 14 for filter media.

Air-to-Refrigerant Coil

The air-to-refrigerant heat exchanger is constructed of staggered copper tubes with die-formed corrugated lanced aluminum fins. The fins are then mechanically bonded to the tubes through expansion.

The coil is placed internal of the unit design for the GEH model to provides an optional dual filtration application. With dual filtration to the GEH unit, maintenance to the filter is significantly less than with a single filtration system. This design also offers maximum flexiblity of the supply and return air configurations.

The maximum working pressure for both the GEH and GEV coils is 450 psig. It is designed for maximum capacity with an additional benefit of physical unit size reduction.

Coil specifications for both GEH and GEV models may be found on in the General Data section on page 36 of this catalog. See Figure 15 for internal air to refrigerant coil placement.

Figure 13: Blower motor (direct drive)

Figure 14: Filter media

Figure 15: Internal air-to-refrigerant coil placement (model GEH)

8 WSHP-PRC001-EN

Features and Benefits

The sound package for the horizontal unit includes:

Table 1: Sound Package (GEH units ONLY)

Enhanced Sound Attenuation

Package (Standard)

18-gauge compressor enclosure

18-gauge single wall front panel

lined compressor enclosure with 1/2-inch cabinet insulation

Deluxe Sound Attenuation

Package (Option)

16-gauge compressor enclosure

16-gauge single wall front panel

lined compressor enclosure with 1/2-inch cabinet insulation

compressor discharge muffler compressor discharge muffler

12-gauge compressor/water-to-refrigerant heat exchanger pan with second stage of vibration isolation

compressor vibration isolation compressor vibration isolation

water-to-refrigerant heat exchanger vibration isolation

lengthwise unit base stiffeners lengthwise unit base stiffeners

3/32-inch foam gasket sealant placed around the compressor and end panel perimeter

Sound Attenuation Package

Testing of conventional units has identified that the sound radiated by the casing of the unit is an important component of the sound that reaches occupants, especially when the unit is located directly over the occupied space.

This sound reduction package reduces radiated noise from the cabinet. Trane double-isolates the compressor and single-isolates the co-axial coil in the unit. This design absorbs the vibration that contributes to radiated sound For sound critical spaces, an enhanced sound package as described in Table 1 provides additional attenuation.

Complete sound data taken in accordance with ARI 260 is available for all units. The test data reflects multi-speed fan motor along a single system curve.

Dual Filtration

Flexibility of the GEH allows for dual filtration in a free return application.

With the field installed dual filtration accessory, filter maintenance of the unit is significantly less. The accessory package includes both the bottom and top filter rack, and one, 1-inch or 2-inch filter. Table 2 provides dual filtration accessory numbers appropriate to unit size.

Table 2: Dual filter accessory kit

numbers

Unit Size

1-inch

Filter

006-015 4474 0630 0100 4474 0634 0100

018-030 4474 0631 0100 4474 0635 0100

036, 042 4474 0632 0100 4474 0636 0100

048, 060 4474 0633 0100 4474 0637 0100

1-i n ch

Filter Kit Part

No.

2-inch

Filter Kit Part

No.

Figure 16: Dual filtration accessory

WSHP-PRC001-EN 9

Boilerless Control/Electric Heat

(option)

In cooling dominant regions where heat may be used 15 to 30 days out of the winter season, eliminating the boiler may be an economical advantage to the building owner. Eliminating a boiler from the system reduces costs associated with the mechanical system installation, as well as the maintenance and service of the boiler.

How can heat be provided for the few days of the year when heat is necessary? Through the water-source heat

pump of course. The advantage of the water-source heat pump is it’s ability to provide heat recovery within the closed water-loop. While some WSHPs may be extracting heat from the closed water loop, other WSHPs may be adding heat to the closed water loop. This creates a perfect system balance for heat sharing or movement from one space to another.

But when water temperatures fall in a boilerless system, and no further heat recovery may be made via the closed loop, heat may be added to the space through a boilerless control electric heat option. See Figure 17 for the boil- erless control, electric heat system diagram.

With the boilerless electric heat option, the heat pump encompasses an internal nichrome open wire heating element (factory mounted and wired). It is comprised of a single stage of electric heat designed to invoice an electric heater in place of the compressor in the event entering water temperature falls below 55 F or a field adjusted temperature setting between 25 F to 60 F.

Features and Benefits

Figure 17: Boilerless control, electric heat system

What is NOT available with the boilerless electric heat option?

1 Hot gas reheat

2 Basic 24 volt controls

3 Tracer

4 115 and 575 volt ratings

5 Supplemental or emergency heat applications

ZN510 controls

10 WSHP-PRC001-EN

Boilerless Control/Electric Heat

Heating/Cooling Mode

In heating mode, when the water temperature falls below 55 F (factory setting), the electric heater is energized, locking out the compressor. The systems electric heat source will continue to be utilized for primary heating until the loop temperature rises above 60 F. Once the entering water temperature rises above 60 F, the boilerless controller returns the unit to normal compressor heating operation and locks out the electric heater. This maximizes efficiency from the unit during the few days requiring heat from the mechanical system. See Figure 18 for the factory mounted and wired boilerless control electric heat water-source heat pump. Available as

a single point power connection.

If the unit employs a cooling only unit design, the electric heat contactor is wired directly to the thermostat for primary heating, and the compressor contactor for cooling.

Note: For geothermal applications, the boilerless controller has an adjustable setting of 25, 35, 45, 55 and 60 degrees.

Features and Benefits

Figure 18: Boilerless control, electric heat water-source heat pump

WSHP-PRC001-EN 11

Features and Benefits

Figure 19: Model GEH with waterside economizer package

Note: Condensate overflow is not available with

the waterside economizer option.

Figure 20: Waterside economizer system

Waterside Economizer (option)

The beauty of the waterside economizer is it’s ability to take advantage of any loop condition that results in cool water temperatures. A prime example would be during fall, winter and spring when cooling towers have more capacity than required and could be controlled to lower temperatures for economizer support.

Another more common inexpensive means of free comfort cooling includes buildings systems where perimeter heating and core cooling are needed. In this system, the perimeter units extract heat from the building loop while in the heating mode, forcing the building loop temperature to drop. Where as, the core are of a building may require cooling in summer or in winter based upon lighting, people and equipment.

If the water-source system design contained an economizing coil option, the moderate temperature loop water circulated through a core water-source system can provide an inexpensive means to satisfy room comfort without operating the water-source heat pump’s compressor.

During economizer mode, fluid enters the unit, and passes by a water temperature sensing bulb. This temperature sensing bulb determines whether the two position, three-way valve will direct the water through the waterside economizing coil, and to the heat pump condenser, or through the condenser only. If the water temperature is 55 F or less, fluid will flow into the economizing coil, while simultaneously halting mechanical operation of the compressor. Mechanical cooling will continue on a call for second stage from the thermostat.

The factory built waterside economizer is available on all 1/2 to 5 ton GEH models.The 1/2 through 5-ton GEV may be ordered to accept a field provided waterside economizing package.

12 WSHP-PRC001-EN

Features and Benefits

Hot Gas Reheat (option)

For space conditioning and climate control, Trane provides an accurate and cost effective dehumidification control through a hot gas reheat option. This option is designed to accommodate unit sizes 012, 036, 048, and 060

With this reheat option, the return air from the space is conditioned by the air-to-refrigerant coil, then reheated by the reheat coil to control not only the space temperature, but to also reduce the relative humidity of the space. The moisture removal capability of a specific heat pump is determined by the units latent capacity rating.

When operating in the reheat mode (meaning the sensible temperature has been met in the space), the humidistat signals the reheat relay coil to energize, allowing the high pressure refrigerant gas to flow from the (1) compressor, through the (2) reheat valve, into the (3) reversing valve, or through the (4) reheat coil for dehumidification. A switching relay has been provided for the reheat application to adjust the blower motor from normal operation to low speed when hot gas reheat is energized.

Note: Trane places an air separation space between the air-to-refrigerant coil, and the reheat coil to allow for maximum moisture removal.

Common Reheat Applications

The hot gas reheat option is designed to support building applications requiring fresh-air ventilation units delivering unconditioned-air directly to the space. It also provides dehumidifi-

cation to large latent load spaces such as auditoriums, theaters and classrooms, or anywhere humidity control is a problem.

Do’s and Don’ts in Design

The factory installed hot gas reheat option is only available with Deluxe or ZN524 controls packages.

A high static blower motor option will be required to support the hot gas reheat option for the 1/2 through 5 ton equipment.

Water regulating valves should not be used with the hot gas reheat option. Trane places a thermal expansion valve on all water-source heat pumps, as well as ground-source heat pumps, to regulate refrigerant flow vs. water flow, making the heat pump more efficient to run.

Water-source heat pumps with hot gas reheat should not be used as a make-up air unit.

Figure 21: Hot gas reheat heat pump

WSHP-PRC001-EN 13

Features and Benefits Controls

Controls by Trane

Whether involved in a retrofit or new construction application, Trane has the control design to fit your system requirement. Our control options provide a broad range of packages from the most cost efficient 24 volt standalone to a complete building automation solution, Trane is the right choice in comfort gratification. The following chart provides a brief overview in the different control combinations.

Graphic Description Application ICS Protocol Where to find

Basic 24V

Deluxe 24V

Tracer ZN510

Tracer ZN524

Used in

single circuited

WSHPs with HGR,

WSE, or BEH.

TracerTM Loop

Controller

Tracer Summit®

Compressor lockout relay, low and high pressure switches.

24 volt microprocessor designed to provide control of the entire unit, as well as multiple relay offerings to maximize system performance. Can connect to a 24V thermostat.

Direct Digital Control board designed to provide control of the entire unit as well as outputs for unit status and fault detection.

Microprocessor-based controller that coordinates the water side (boiler, pumps, cooling tower, etc.) of a water-source heat pump system.

Microprocessor based controller that coordinates full building automation from HVAC to lighting.

Retrofit market where single and multiple unit replacement occurs.

New building design where field provided controls are specified.

Retrofit market where single and multiple unit replacement occurs.

Multi-unit installation where units may be daisychained directly to the

Trane Tracer troller.

Retrofit market where overall system upgrade is specified.

Multi-unit (100+) installation where units are linked by a common twisted pair of wire for a communication link.

Retrofit market where overall system upgrade is specified.

Multi-unit (100+) installation where units are linked by a common twisted pair of wire for a communication link.

Wherever the Tracer ZN510 controls or 24 volt electro-mechanical controls are specified for complete control of the water loop and pumps.

Where any controller is specified.

Loop Con-

No Non Applicable Page 15

No Non Applicable Page 16

Yes

Yes SCC LonTalk

Yes LonTalk

Yes BA Cn et

SCC LonTalk open protocol

(Comm5)

open protocol

(Comm5)

compatible

(Comm5)

(Comm 2,3,4,5)

Page 18

WSHP-MG-3

EMTW-SVN01B-EN EMTW-SVP01B-EN EMTW-SVU01B-EN

HGR = Hot Gas Reheat

WSE = Waterside Economizer

BEH = Boilerless Electric Heat

14 WSHP-PRC001-EN

Features and Benefits Basic Controls

Figure 22: Basic 24 volt control box

Figure 23: Safety devices

Figure 24: 24 volt stand-alone system

Basic 24 Volt Controls

The basic 24 V electromechanical unit control provides component protection devices for maximum system reliability. Each device is factory mounted, wired and tested. See Figure 22 for the unit control box.

Safety Devices

System safety devices are provided through the use of low/high pressure switches in the refrigeration circuit to help prevent compressor damage.

The switch and sensor are set to activate at refrigerant pressures of 20 psig to fit most applications.

In cases where a low charge, or excessive loss of charge occurs, each compressor comes equipped with an external overload device to halt the compressor operation.

The high pressure switch prevents compressor operation during high or

excessive discharge pressures that exceed 395 psig.

A lockout relay provides the mechanical communication of the low and high pressure switches to prevent compressor operation if the unit is under low or high refrigerant circuit pressure, or during a condensate overflow condition. The lockout relay may be reset at the thermostat, or by cycling power to the unit.

General alarm is accomplished through the lockout relay and is used in driving light emitting diodes. This feature will drive dry contacts only, and cannot be used to drive field installed control inputs.

See Figure 23 for unit safety devices on the basic 24V control unit.

Stand-alone System

The 24 volt electro-mechanical design may be applied as a stand-alone control system. The stand-alone design provides accurate temperature control directly through a wall-mounted mercury bulb or electronic thermostat. This system set-up may be utilized in a replacement design where a single unit retrofit is needed. It may be easily interfaced with a field provided control system by way of the factory installed 18-pole terminal strip.

This stand-alone control is frequently utilized on small jobs where a building controller may not be necessary, or where field installed direct digital controls are specified. This type of control design does require a constant flow of water to the water source heat pump. With a positive way to sense flow to the unit, the units safety devices will trigger the unit off.

The stand-alone system design provides a low cost option of installation while still allowing room control for each unit. See Figure 24 for 24 volt stand-alone system controls.

WSHP-PRC001-EN 15

Features and Benefits Deluxe Controls

Deluxe 24V Electronic Controls

The deluxe 24V electronic unit control provides component protection devices similar to the basic design, but contains upgraded features to maximize system performance to extend the system life. Each device, is factory mounted, wired, and tested in the unit. See Figure 25 for unit control box.

Small Building Control

The deluxe 24V electro-mechanical design may be applied as a stand-alone control system or as a multi-unit installation system. With a stand-alone design, units run independently of one another with a mercury bulb or electronic digital thermostat.

With a multiple unit installation, the units may be daisy-chained directly to the Trane Tracer loop controller (TLC), pump(s), boiler, and tower for a complete networked water-source system. The TLC provides a night setback output, and a pump request

input for system optimization.See Figure 26 for 24 volt deluxe control system.

Figure 25: Deluxe 24 volt control box

Figure 26: 24 volt deluxe control system

16 WSHP-PRC001-EN

Features and Benefits Deluxe Controls

Microprocessor Design

The 24 volt deluxe design is a microprocessor-based control board conveniently located in the control box. The board is unique to Trane water-source products and is designed to control the unit as well as provide outputs for unit status and fault detection.

The Trane microprocessor board is factory wired to a terminal strip to provide all necessary terminals for field connections. See Figure 27 for the deluxe 24V control board.

Figure 27: Deluxe 24V control board

Deluxe 24V features include:

Random Start

The random start relay provides a time delay start-up of the compressor when cycling in the occupied mode. A new start delay time between 3 and 10 seconds is applied each time power is enabled to the unit.

Anti-short Cycle Timer

The anti-short cycle timer provides a three minute time delay between compressor stop and compressor restart.

Brown-out Protection

The brown-out protection function measures the input voltage to the controller and halts the compressor operation. Once a brown-out situation has occurred, the anti-short cycle timer will become energized. The general fault contact will not be affected by this condition. The voltage

will continue to be monitored until the voltage increases. The compressors will be enabled at this time if all start-up time delays have expired, and all safeties have been satisfied.

Compressor Disable

The compressor disable relay provides a temporary disable in compressor operation. The signal would be provided from a water loop controller in the system. It would disable the compressor because of low water flow, peak limiting or if the unit goes into an unoccupied state. Once the compressor has been disabled, the anti-short cycle time period will begin. Once the compressor disable signal is no longer present, and all safeties are satisfied, the control will allow the compressor to restart.

Generic Relay

The generic relay is provided for field use. Night setback or pump restart are two options that may be wired to the available relay. (Note: Night setback is available as factory wired). An external Class II 24VAC signal will energize the relay coil on terminals R1 and R2. Terminals C (common), NO (normally open), and NC (normally closed) will be provided for the relay contacts.

Safety Control

The deluxe microprocessor receives separate input signals from the refrigerant high pressure switch, low suction pressure switch and condensate overflow.

In a high pressure situation, the compressor contactor is de-energized, which suspends compressor operation. The control will go into soft lock- out mode initializing a three minute time delay and a random start of 3 to 10 second time delays. Once these delays have expired, the unit will be allowed to run. If a high pressure situation occurs within one hour of the first situation, the control will be placed into a manual lockout mode, halting compressor operation, and initiating the general alarm.

In a low temperature situation, the low pressure switch will transition open after the compressor starts. If the switch is open for 45 seconds during compressor start, the unit will go into soft lockout mode initializing a three minute time delay and a random start of 3 to 10 second time delays. Once these delays have expired, the unit will be allowed to run. If the low pressure situation occurs again within 30 minutes, and the device is open for more than 45 seconds, the control will be placed into a manual lockout mode, halting compressor operation, and initiating the general alarm.

In a condensate overflow situation, the control will go into man- ual lockout mode, halting compressor operation, and initiating the general alarm.

The general alarm is initiated when the control goes into a manual lockout mode for either high pressure, low pressure or condensate overflow conditions.

Diagnostics

Component device connections to the microprocessor board are referenced in Figure 27. Three LEDs (light emitting diodes) are provided for indicating the operating mode of the controller. See the unit IOM for diagnostics or troubleshooting through the use of the LEDs.

WSHP-PRC001-EN 17

Features and Benefits ZN510 & ZN524 Controls

Tracer ZN510 & ZN524 Controls

The Tracer ZN510 and ZN524 are direct digital control (DDC) systems specifically designed for single and dual circuited water-source equipment to provide control of the entire unit, as well as outputs for unit status and fault detection. Each device is factory installed, commissioned, and tested to ensure the highest level of quality in unit design. Each of the controller’s features and options were selected to coordinate with the unit hardware to provide greater energy efficiency and equipment safety to prolong the equipment life.

In addition to being factory configured for control of the unit fan, compressor and reversing valve, the ZN510 and ZN524 controllers are designed to coordinate the waterside of the water-source system through the Tracer Loop Controller (TLC). If applied in a peer-to-peer communication environment, data between similar controllers may be exchanged without requiring a building automation system.

By teaming the ZN510 and ZN524 with the TLC, a low first-cost for the mechanical equipment, water loop, and water pump optimization is provided to the owner.

For owners who require a full building integrated "open protocol" system, The ZN510/ZN524/TLC application is upgradable to support complete building control through Tracer Summit. Because the ZN510 and ZN524 is LonTalk certified, it is capable of working with, and talking to other LonTalk cer-

tified controllers providing the building owner more choices, and the design engineers more flexibility to meet the challenges of building automation. See Figure 28 for ZN510 control box.

Figure 28: ZN510 control box

18 WSHP-PRC001-EN

Features and Benefits ZN510 & ZN524 Controls

Direct Digital Controls

When the ZN510 or ZN524 controller is linked directly to the Tracer Summit, each Tracer Summit building automation system can connect a maximum of 120 Tracer ZN510 or ZN524 controllers. See Figure 29 for the Tracer ZN524 board.

Figure 29: Tracer ZN524 controller

Tracer ZN510 and ZN524 functions include:

Compressor Operation

The compressor is cycled on and off to meet heating or cooling zone demands. Single and dual compressor units use the unit capacity and pulse width modulation (PWM) logic along with minimum on/off timers to determine the compressor’s operation. The compressor is controlled ON for longer periods as capacity increases and shorter periods as capacity decreases.

Random Start

To prevent all of the units in a building from energizing major loads at the same time, the controller observes a random start from 0 to 25 seconds. This timer halts the controller until the random start time expires.

Reversing Valve Operation

For cooling, the reversing valve output is energized simultaneously with the compressor. It will remain energized until the controller turns on the compressor for heating. At this time, the reversing valve moves to a de-energized state. In the event of a power failure or controller OFF situation, the reversing valve output

will default to the heating (de-energized) state.

Fan Operation

The supply air fan operates at the factory wired speed in the occupied or occupied standby mode. When switch is set to AUTO, the fan is configured for cycling ON with heating or cooling. In heat mode, the fan will run for 30 seconds beyond compressor shutdown in both occupied and unoccupied mode.

Fan Run Timer

The controller’s filter status is based on the unit fan’s cumulative run hours. The controller compares the fan run time against an adjustable fan run hours limit and recommends unit maintenance as required.

Data Sharing

The Tracer ZN510/ZN524 controller is capable of sending or receiving data (setpoints, fan request, or space temperature) to and from other controllers on the communication link. This allows multiple units to share a common space temperature sensor in both stand-alone and building automation applications.

Night Setback

The four operations of the Tracer ZN510/ZN524 controller include occupied, occupied standby, occupied bypass and unoccupied.

In an occupied situation, the controller uses occupied heating and cooling setpoints to provide heating and cooling to the building. This occupied operation is normally used during the daytime hours when the building is at the highest occupancy level.

In an occupied standby situation, the controllers heating and cooling setpoints are usually wider than the occupied setpoints. This occupied standby operation is used during daytime hours when people are not present in the space (such as lunchtime or recess). To determine the space occupancy, an occupancy sensor is applied.

In an unoccupied situation, the controller assumes the building is vacant, which normally falls in evening hours when a space may be empty. In the unoccupied mode, the controller uses the default unoccupied heating and cooling setpoints stored in the controller. When the building is in unoccupied mode, individual units may be manually placed into timed override of the unoccupied mode at the units wall sensor. During timed override, the controller interprets the request and initiates the occupied setpoint operation, then reports the effective occupancy mode as occupied bypass.

In the occupied bypass mode, the controller applies the occupied heating and cooling setpoint for a 120 minute time limit.

High and Low Pressure Safety Controls

The Tracer ZN510/ZN524 controller detects the state of the high pressure or low pressure switches. When a fault is sensed by one of these switches, the corresponding message is sent to the controller to be logged into the fault log. When the circuit returns to normal, the high pressure control and low pressure control automatically reset. If a second fault is detected within a thirty-minute time span, the unit must be manually reset.

Condensate Overflow

When condensate reaches the trip point, a condensate overflow signal generates a diagnostic which disables the fan, unit water valves (if present), and compressor. The unit will remain in a halted state until the condensation returns to a normal level. At this time, the switch in the drain pan will automatically reset. However, the controller’s condensate overflow diagnostic must be manually reset to clear the diagnostic and restart the unit.

WSHP-PRC001-EN 19

Features and Benefits ZN510 & ZN524 Controls

Additional Functions of the ZN524 Controller

When the building owners choice is Trane Tracer controls, the ZN524 controller is required when any of the following applications are selected on a single and dual circuited equipment.

• Waterside Economizer

• Hot Gas Reheat (for Dehumidification)

• Boilerless Control for Electric Heat

• Water Isolation Valve Control (for Variable Speed Pumping)

Entering Water Temperature Sampling

The ZN524 controller will sample the entering water temperature to determine proper control action for units equipped with boilerless electric heat or waterside economizer.

Waterside Economizer: Entering water temperature (EWT) sampling will automatically occur at power up when the unit is equipped with a waterside economizer (WSE). The EWT is used to determine if economizing is feasible. When the conditions are met, the isolation valve(s) are driven open for three minutes and the EWT reading is taken. The determination as to whether or not the economizer can be enabled will be made and the controller will take appropriate action. The isolation valve will remain open regardless if the WSE or the DX cooling is enabled.

The unit’s waterside economizer will contain a 2-position water valve wired to the ZN524. The economizing water coil will be optimized to provide 100% of the unit capacity at 80.6 F/66.2 F return air temperature with 45 F entering water. The flow rate is established at 86 F entering water temperature and 96 F leaving water temperature.

Low leaving air protection will be furnished to protect the unit against delivering air that is cold enough to sweat discharge air grilles. Coil icing protection will also be provided.

Waterside economizer cooling will be active during occupied, unoccupied and standby cooling modes.

Boilerless Control Electric Heat and Supplemental Electric Heat:

The ZN524 supports a single stage of boilerless electric heat operation or concurrent heating. When the unit is configured for boilerless control, the EWT will be used to determine whether DX heating should be disabled and the electric heater enabled. When these conditions are met, the isolation valve(s) are driven open for three minutes and the entering water temperature reading is taken. The determination as to whether or not to utilize electric heat will be made and the controller will take appropriate action. If boilerless electric heat is enabled, then the isolation valve will be closed, shutting down the water flow to the unit.

When the unit is configured for concurrent operation of DX heating (compressor in heat pump mode) and electric heat, the electric heat will act as a second stage of heat for single compressor units, and a third stage of heat for dual compressor units. Note:

With concurrent (or supplemental) electric heat, the electric heater is field provided.

Water Isolation Valves

Variable speed pumping systems are supported by the ZN524 controller when water isolation valves are present. Up to two isolation valves are supported by the controller (one for each compressor circuit).

The valves are normally closed unless DX heating, DX cooling, waterside economizer or dehumidification is requested. When the isolation valves are driven open for operation, the outputs will be driven for 20 seconds to ensure

adequate water flow before the compressor outputs are energized. Once an isolation valve has been opened, it will remain open for a 10 minute minimum to reduce excessive cycling of the valve.

Dehumidification

Dehumidification for the single and dual circuited water-source heat pump is applicable with the ZN524 controller. The controller is capable of directing one stage of DX cooling in conjunction with one stage of reheat (hot gas reheat).

Dehumidification can only occur when the controller is in the cooling mode. A humidity transmitter is used to measure the zone’s relative humidity (RH), then compares the zone relative humidity to the relative humidity enable/ disable setpoint parameters. The default values for dehumidification enable is 60% RH with the disable point at 52% RH. These values are configurable.

20 WSHP-PRC001-EN

Features and Benefits ZN510 & ZN524 Controls

Building Control Advantages

The Tracer ZN510/ZN524 controller has the ability to share information with one or several units on the same communication link. This sharing of information is made possibe via a twisted pair of wire and a building automation system or through Trane’s Rover

An advantage of installing a ZN510/ZN524 is its capability to work with other LonTalk certified controllers. This provides greater flexibility to the building owner, as well as greater flexibility in design.

Integrating the ZN510/ZN524 on water-source equipment, and tying it to a Tracer Summit system provides a complete building management system. Each Tracer Summit can connect to a maximum of 120 controllers. With the ICS system, the Tracer can initiate an alarm on a loss of performance on equipment malfunctions; allowing problems to be handled in a timely manner before compromising comfort.

This type of application would most commonly be used for a large space(s) that

service tool .

may require more than one unit. In addition to

this application design, the Tracer

ZN510/ZN524 controller provides a way for units located within the same space to share the same zone sensor to prevent units from simultaneously heating and cooling in the same space.See Figure 30 for Tracer ZN510/ZN524 controller system.

Figure 30: Tracer ZN510/ZN524 controller system

WSHP-PRC001-EN 21

Application Considerations

Flexibility

The high efficiency vertical and horizontal water-source heat pump system is versatile for installation in boiler/cooling tower applications, as well as ground-source (geothermal) applications. The system design may employ either a central pumping design, or a distributed pumping design.

A central pumping design involves a single pump design, usually located within a basement or mechanical room to fulfill pumping requirements for the entire building system. An auxiliary pump is typically applied to lessen the likelihood of system downtime if the main pump malfunctions.

A distributed pumping system contains a single pump module connected directly to the units supply and return. This module is field installed and piped to the unit. This design requires individual pump modules specifically sized for each water-source heat pump.

Advantages of Geothermal

The advantages of a geothermal heat pump system could literally cut a business’ heating and cooling costs by 30 to 40-percent. The units are durable, and typically last longer than conventional systems because they are protected from harsh outdoor weather conditions, and because the unit is installed indoors and the loop underground. (According to ASHRAE, the estimated service life for a commercial water-to-air heat pump is 19-years.) Geothermal heat pumps have fewer mechanical components, making them more reliable and less prone to failure. Manufacturers of the loop materials guarantee their products for up to 25-years, with no maintenance required.

Geothermal heat pumps work toward the preservation of the environment by reducing the environmental impacts of electric power generation.

A ground source (geothermal) system consist of a:

• A ground water heat pump

• A closed loop ground heat exchanger made of high density polyethylene pipe (guaranteed 25- years or more by many manufacturers); and

• A low wattage circulating pump(s)

The fluctuating temperatures of fluid from the earth are more stable than air, allowing the equipment to operate at a lower discharge pressure and use fewer kilowatts. The constant earth temperature will heat or cool the fluid running through buried high density polyethylene pipe to provide heating and cooling to a building.

Figure 31: Geothermal energy recovery loop

A geothermal loop can be installed either horizontally or vertically. Vertical loops require less overall land area to reject (i.e., sink) the excess heat from the building. Horizontal loops require trenches in the ground spanning a larger overall land area.

Although external piping is the responsibility of the installer and/or piping manufacturer, many electric utilities and rural electric cooperatives are offering monetary incentives to install geothermal systems. Utility companies offer the incentives because of reduced peak loads that flatten out their demand curve over time, and save them money. These savings are ultimately transferred to the consumer. See Figure 31 for geothermal energy recovery loop.

22 WSHP-PRC001-EN

Application Considerations

Central Pumping System

Units that employ a central pumping system contain single or dual pumps to fulfill pumping requirements for the entire building system.

The central system’s supply and return lines should be sized to handle the required flow with a minimum pressure drop.

The water-source heat pump (in this case a high efficiency GEH) may include add-on accessories to help aid in system balancing, acoustics and safety requirements. Some of these items may be ordered from the factory, then field installed. Many are provided by the contractor.

Hose kits are used to connect the water supply and return line to the water inlets and outlets. Trane offers various hose kit combinations to better facilitate system flow balancing. These flexible hoses also aid in the reduction of vibration between the unit and the rigid central piping system.

A two position isolation valve is often applied to systems which incorporate variable frequency pumping. This valve is capable of stopping/starting water flow to the unit, which in-turn reduces the pumping requirements for the entire system.

The central system supply and re-

turn lines should be sized to handle the required flow with a minimum pressure drop.

Note: Pipe will sweat if low temperature water is below the dew point of the surrounding space. Trane recommends that these lines be insulated to prevent damage from condensation when condenser loop is designed to be below 60 F. Equipment installed in attic/crawl space temperatures be-

low 40°F may require antifreeze in the water loop.

For acoustically sensitive areas, a

six-inch deep fiberglass insulation is recommended to be field installed below the horizontal unit. This field supplied insulation should be approximately twice the footprint size of the unit. It provides sound damping of the unit while in operation.

The unit’s (item 2) 3/4-inch

high voltage and (item 3) 1/2-inch

low voltage connections are located on the left chamfered corner of the unit. They are designed to accept conduit.

A field supplied line voltage dis-

connect should be installed for branch circuit protection. Check local codes for requirements.

WSHP-PRC001-EN 23

Application Considerations

Distributed Pumping System

A distributed pumping system contains either a single or dual pump module, specifically sized for each water-source heat pump, then connected directly to the units supply and return lines.

The distributed system’s supply and return lines should be sized to handle the required flow with a minimum pressure drop.

Hose kits are used to connect the

water supply and return line to the water inlets and outlets. Trane offers various hose kit combinations to better facilitate system flow balancing. These flexible hoses also aid in the reduction of vibration between the unit and the rigid central piping system.

The unit’s (item 2) 3/4-inch high voltage and (item 3) 1/2-inch low

voltage connections are located on the left chamfered corner of the unit. They are designed to accept conduit.

The distributed pumping system supply and return lines should be sized to handle the required flow with a minimum pressure drop.

Note: Pipe will sweat if low tem-

perature water is below the dew

point of the surrounding space.

Trane recommends that these

lines be insulated to prevent dam-

age from condensation when con-

denser loop is designed to be

below 60 F. Equipment installed in

attic/crawl space temperatures be-

low 40°F may require antifreeze in

the water loop.

For acoustically sensitive areas, a six-inch deep fiberglass insulation is recommended to be field installed below the horizontal unit. This field supplied insulation should be approximately twice the footprint size of the unit. It provides sound damping of the unit while in operation.

A field supplied line voltage dis-

connect should be installed for branch circuit protection. Check local codes for requirements.

Trane’s self-contained pump mod-

ule and hose kit make a complete pumping package for distributed pumping systems. The module is designed for circulating commercial loops that require a maximum flow rate of 20 gpm. Each pump module is fully assembled for connection to water and electrical points. The kit contains all of the necessary components for the installation, operation and maintenance of a closed loop application. See WSHPC-IN-5 (72-9006-03) for electrical and dimensional requirements

24 WSHP-PRC001-EN

Application Considerations

Installation of the 1/2 through 5-Ton Vertical

Whether securing the 1/2 through 5-ton GEV to a central pumping system, or a distributed pumping system, Trane recommends a few accessory considerations to the system installation.

The field supplied line

voltage disconnect should be installed for branch circuit protection.

The units (2) 3/4-inch high

voltage and (3) 1/2-inch low voltage connections are located on the left chamfered corner of the unit. They are designed to accept conduit.

Trane recommends that

the condensate system be set-up per negative pressure trapping in consideration of the unit’s draw-through design. With this properly trapped system, when condensate forms during normal operation, the water level in the trap rises until there is a constant outflow.

For acoustically sensitive areas, a 1/2-inch thick field provided vibration pad should be installed below the vertical unit. This field provided piece should be equal to the overall foot-print size of the unit to provide sound damping of the unit while in operation.

Hose kits are used to connect the

water supply and return lines to the water inlet and outlets. Trane includes various hose kit combinations to better facilitate system flow balancing. These flexible hoses, reduce vibration between the unit and the rigid piping system.

WSHP-PRC001-EN 25

Application Considerations

Installation Made Easy

Installing a horizontal unit inside a corridor to enhance sound attenuation provides value to duct design. Trane takes this fact one step further.

The new GEH design offers same side return-air/supply-air access to the unit. This access is contained within the overall dimension of the units length as shown in Figure 32. The duct access to the unit allows the unit to be installed closely against a corridor wall, while at the same time eliminating space required for the duct design.

Most horizontal unit designs provide an opposite supply air from the return air arrangement, or an end supply arrangement option. See Figure 33 for end-supply example. An end-supply design increases the overall unit length of the system to accommodate a 90-degree duct turn. This not only requires added space, but also adds cost in both materials and installation.

Additional value to the design is acquired through the same side supply/return-air design. This design eliminates a requirement for a four sided service access. When installing the same side return/supply-air access, a brief 3-inch minimum is all that is required between the unit and the wall.

Figure 32: Same-side supply/return-air Figure 33: End supply arrangement/ductwork

26 WSHP-PRC001-EN

Duct Design for Noise Control

Proper acoustics are often a design requirement. Most of the problems that are associated with HVAC generated sound can be avoided by properly selecting and locating the components of the system. Acoustical modeling should be used to find the lowest cost design to meet a specific sound requirement, however, there are some general do’s and don’ts that should be observed.

Figure 34 shows a supply air duct that is placed too close to the blower to provide substantial noise attenuation. It also, represents the effects on sound that a short supply branch connected to the discharge may produce. Avoid these forms of connections when designing ductwork where noise attenuation is critical. The following suggestions will reduce the amount of sound that reaches the ocupied space:

Application Considerations

Figure 34: Improper supply-air ducting

• Design the duct run with two 90-degree turns

• Line the first 5 feet of the supply trunk

• Line elbows and transition pieces, as well as a short distance upstream and downstream of the fittings

• Use flexible connections to isolate vibrations

• Provide multiple discharges

• Keep duct velocity low

See Figure 35 for a positive representation of supply duct work design for noise attenuation on units over 1 1/2 tons.

WSHP-PRC001-EN 27

Figure 35: Desired supply-air ducting

Figure 36: Improper return-air ducting

Application Considerations

Sound control applies to the return side of the duct design as well as the supply side. Figure 36, demonstrates a poor installation. Note that the return air opening is close to the cabinet of the unit.

Figure 37 graphic represents proper installation of return-air duct. This

includes

• Two 90-degree bends prior to the intake

• Lining the first 10 feet of the return air duct

• Locating the return-air intake away from the unit blower

A duct system with noise control in-mind can be designed by:

• Keeping air flow velocities low

• Using aerodynamic fittings

• Using a duct liner if metal duct is applied

Figure 37: Proper return-air ducting

• Avoiding line-of-sight connections between a noise source and an outlet

• Avoiding line-of-sight connection

between a noise source and an

inlet

• By properly locating balancing dampers

• Sealing cracks, seams and joints in the duct run and equipment panels

• Blocking transmission through walls, ceiling and floors

• Mounting and supporting the ductwork with isolation devices that absorb vibration

• Using flexible duct connections

• Using flexible braided hoses on the water connections

28 WSHP-PRC001-EN

Application Considerations

Using Water Regulating Valves

The function of the water regulating valve assembly is to minimize the amount of water which flows through the water-source heat pump. These valves are most often used in systems where the water is wasted, but may also be used in boiler/cooling tower involving variable speed pumping. In a variable speed application, the valves are used to meter desirable water flow through the unit when the unit is running, and to stop water flow when the unit is not running (but may not in- clude a 100% shut-off).

The water regulating valve assembly consists of two valves piped in parallel. When the water-source heat pump’s compressor is de-energized, both valves are closed, allowing no water to flow through the unit. But, when the unit compressor is energized, one of the valves is closed and the other valve will allow water flow through the unit.

In cooling mode, the valve controlling the water flow is referred to as a direct acting valve. As the spring tension increases, the head pressure will also increase. This is due to the decrease in water flow through the unit. Note, the valve is being controlled by the head pressure. As the head pressure increases, the water flow increases, and vice versa. The valve is controlled by two pressures. The refrigerant pressure in the high side of the system, and the spring pressure, acting on the opposite side of the valve.

Note: The spring tension on the direct acting valve may be adjusted to maintain a desired head pressure.

When the unit is OFF, or is in the heating mode, the valve closes. This is because the pressure acting on the valve is out of the spring set-range.

In the heating mode, the valve controlling the water flow is referred to a a reverse acting valve. As the spring tension increases, the suction pressure will increase. This is due to the increase in water flow through the unit. Note, the valve is being controlled by the suction pressure. As the suction pressure decreases, the water flow increases, and vice versa. The valve is controlled by two pressures. The refrigerant pressure in the low side of the system, and the spring pressure, acting on the opposite side of the valve.

Note: The spring tension on the reverse acting valve may be adjusted to maintain a desired suction pressure.

When the unit is OFF, or is in the cooling mode, the valve closes. This is because the pressure acting on the valve is out of the spring set-range.

Both the direct acting and the reverse acting valves should be tapped into the same refrigerant line via a schraeder connection. This line must be a high pressure line when the unit is in the cooling mode, and a low pressure line when the unit is in the heating mode. The only line that will accommodate this condition is the vapor line running between the reversing valve and the water-to-refrigerant heat exchanger.

Note: In many applications, a water regulating valve may be used to meter water flow to the equipment instead of metering refrigerant flow to the equipment. This is typically applied when the equipment does not contain a thermal expansion refrigerant metering device. Trane places a thermal expansion valve on all water-source and ground-source heat pumps to provide maximum performance of the equipment. Capillary tube assemblies are not used on Trane water-source or ground-source heat pump equipment. Therefore, a water regulating valve is not required on most equipment applications.

WSHP-PRC001-EN 29

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Trane WSHP-PRC001-EN User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Table of Contents