Trane Tracer, ZN510 User Manual

WSHP-IOP-2 May 1998

Installation, Operation, and Programming

Tracer™ ZN510 Controller

Literature History

The Trane Company has a policy of continuous product improvement and it reserves the right to change specifications and design without notice.

Installation, Operation, and Programming

Library Service Literature

Product Section Unitary

Product Water-Source Heat Pumps

Model 000

Literature Type

Sequence 1

Date April 1998

File No. SL-UN-000-WSHP-IOP-2-0498

Supersedes New

Related Literature

z CNT-IOP-1 ZN510 1 Controller:

Installation, Operation, and Programing

z WSHP-PD-1 Water-Source Heat

Pump Controller Product Data Sheet

WSHP-IOP-2

Installation, Operation, and Programming

z WMCA-PD-1 ZN510 Loop Con-

troller Product Data sheet

z WSHP-IOP-3 ZN510 Water-

Source Heat Pump Controller Installation, Operation, and Programming Guide

z WMCA-IOP-1 ZN510 Controller

Installation, Operation, and Programming Guide

Start-up Procedure 4 Power-up Sequence 5 Unit Identification Tag 6 Unit Operation 7

General Information 7 Communication 7 Power 8 Binary Outputs 8 Analog Outputs 9 Binary Inputs 9 Analog Inputs 12

Zone Sensors 15 Heating or Cooling Control

Mode Operation Single or Dual Compressor

Operation Data Sharing 20 Configuration 21 Troubleshooting 22 Diagnostics 27 ZN510 Controller Replacement 28 Wiring Diagram 29 Hardware Specifications 31 Appendix 33

Start-up Procedure

Installation of New Units

1. Follow all instruction for

installation of water source heat pumps as detailed in the IOM (Installation Operation Maintenance manual).

2. Disconnect power or disable

the circuit breaker to unit.

3. Run communication link wire to

field terminal strips 14 and 16. (See wiring diagram in the unit).

4. Install zone sensor to low

voltage control terminals 1 through 6. (See wiring diagram in the unit and zone sensor submittals).

Zone Sensor Placement

Zone sensor location is an important element of effective room control and comfort.

The best sensor location is typically on a wall, remote from the Readings at this location assure that the desired setpoint is achieved across the space, not just near the unit itself. It may be necessary to subdivide the zone with multiple units to ensure adequate control and comfort.

HVAC unit.

5. Verify that water connections

have been made to unit, then ensure that water is circulating through the unit.

6. Reapply power.

7. Check for STATUS GREEN LED

operation to ensure power and communication has been made

to the ZN510

Peel IDENTIFICATION TAG from unit and place in the ZN510 IOP, on a copy of Sheet 6 of this document, or on building plans for future location use. The actual room location on the tag may be hand written.

The following are typical areas where the zone sensor should not be mounted:

z Near drafts or “dead spots”

(e.g., behind doors or corners)

z Near hot or cold air ducts

z Near radiant heat (e.g., heat

emitted from appliances or the sun)

z Near concealed pipes or

chimneys

z On outside walls or other non-

conditioned surfaces

™

z In air flows from adjacent zones

or other units

Power Up Sequence

When 24 VAC power initially is applied to the ZN510 controller, the following sequence occurs:

1. All outputs are controlled off.

2. The controller reads all inputs

to determine their initial values.

Note: Because the space temperature can be hardwired to the controller or communicated, the controller waits for several minutes to check for the presence of a communicated value.

3. A random start time is hard

coded on every board and cannot be disabled. The board generates a random time delay between 0 and 25 seconds. Once this time expires, the power up control wait time (if configured) will wait for 120 seconds. The power up control wait allows ample time for a communicated request to arrive. If the power up control wait time expires, and the controller does not receive a communicated occupancy command, the unit assumes stand alone operation.

4. Normal operation begins.

Unit Identification Tag

The unit identification tag is factory mounted and provided for easy identification of an installed unit. It contains model number, tagging, and location information. See Figure 1.

The top portion of the unit identification tag remains permanently affixed to the unit for identity purposes. The bottom portion of the tag provides pertinent information that is removable to be placed on building plans or in the ZN510 IOP on page 33. This provides identification history about the unit’s location for quick reference.

These tags provide information about unit location, unit serial number, and NID (neuron identification number). The NID is similar to the serial number of the unit but is specific to the identification of the ZN510 Board. The location identification is a customer defined, clear English description, of the unit’s physical location. This is a 27 character description of the location. For example, if the location identification for a unit is “Conference Room 101”, the ZN510 and Rover (the Trane Comm 5 service tool) will recognize this clear English description so maintenance can be performed on the appropriate unit. If location identification is not defined, it will default to the unit serial number. This provides some information so the user has multiple references to the unit. The blank location is provided for field modification in case the unit is moved from the initial location.

Unit Identification Tag

Figure 1: Unit Identification Tag

Note: Fold and tear carefully along dashed

removable line.

Unit Operation

General Information

The ZN510 controller is a microprocessor-based direct digital controller that controls a variety of water source heat pump equipment including:

z Standard efficiency horizontal

and vertical units up to 10 tons.

z High efficiency horizontal and

vertical units.

Figure 2: Communication connections

Communication

The ZN510 controller communicates via Trane’s Comm5 protocol. Typically, a communication link is applied between unit controllers and a building automation system. Communication is also possible

™

with Trane’s service tool Rover

ZN510 provides a total of six 1/4-inch quick-connect terminals for connection to the Comm5 communication link. These connections include:

z Two terminals (TB2-1, TB2-2)

z Console water source heat

pumps.

ZN510 is designed to provide accurate and reliable zone temperature control by using custom proportional integral (PI) algorithms. The controller is factory installed and configured to support:

z Single fan speed.

are provided for direct connection of Rover to the ZN510 Board or provided as spare terminals.

z Two terminals (TB2-3, TB2-4)

are connected to the field terminal strip (1TB1-14, 1TB1-16) for connection to the communication link (daisy chain).

z Up to two compressors.

z Reversing valve.

z 2-position outdoor air damper

or generic binary output.

Peer-to-peer communication across controllers is possible even when a building automation system is not present. ZN510 is also adaptable as a standalone system.

z Two terminals (TB2-5, TB2-6)

are connected to the field terminal strip (1TB1-5, 1TB1-6) which should be connected to the zone sensor communication jack. This provides direct connect of Rover to the communication link without having to connect directly to the ZN510 board or provided as spare terminals.

z The field terminal strip 1TB1

provides screw terminations for all field connections.

TB2-1

COMM COMM COMM

Space Communication Connection

20 pole low voltage terminal strip screw connections for field hook-up

Figure 3: Communication Wiring

TB2-2

TB2-3

1TB1-14

Communication Link

1TB1-16

TB2-4

TB2-5

TB2-6

1TB1-5

1TB1-6

Zone Sensor

Unit Operation

Power

The ZN510 controller is powered by 24

VAC. A total of two 1/4-inch quick-

connect terminals are provided for 24 VAC connection to the board. See

Figure 4 for ZN510 power requirement.

Note: Power for field installed ancillary devices is not available from the board. It must be tapped at transformer. See Table 21 for excess power available.

Binary Outputs

The ZN510 uses five of its binary outputs to control heat pump units. Outputs are load side switching triacs. The triac acts as a switch by either making or breaking the circuit between the load (reversing valve, damper, contactor, relay) and ground.

See Figure 5 for the configuration of the five binary outputs.

Factory Supplied Transformer

Line

Vol tage

24VAC

Figure 4: Power Connections

Field installed 2 position damper actuator

24VAC

1TB1-17

1TB1-18

2-Position Damper Actuator or Generic Binary Output

Binary output 6 (BOP 6) is factory configured to control a normally closed 2-position outdoor air damper. It may be field modified to control a generic output for control by a building automation system. If set up as a generic output, the controller does not use BOP 6 as part of the normal control. A building automation system must issue commands to control the generic binary output.

Note:

z During occupied mode, the

outdoor air damper is closed when the fan is controlled off.

z During unoccupied mode, the

outdoor air damper normally remains closed.

z 2-position damper must not

exceed 10 VA power output from board.

Figure 5: Binary outputs

BOP 1 (Fan)

BOP 2 (Reversing Valve)

J1-1

J1-2

BOP 4 (Not Used)

J1-4

BOP 5 (Compressor 1)

J1-5

BOP 3 (Not available)

J1-3

Binary Outputs

Table 1: BOP 6 control of a 2-position outdoor air damper

Model Fan Operation Outdoor Air Damper

Occupied

Occupied warm up or cool down

Occupied standby On or cycling Closed

Unoccupied Cycling Closed

Diagnostic present Diagnostic dependent Closed

On or cycling Off

On or cycling Closed

Open Closed

BOP 6 (Compressor 2)

J1-6

BOP 7

J1-7

Unit Operation

Output Overrides

The ZN510 controller includes a manual output test function. Use this feature to manually exercise the outputs in a defined sequence. The purpose of the test sequence, is to verify output and end device operation. Use the manual output test to:

z Verify output wiring and

operation without using Trane’s service tool, Rover.

Analog Outputs

Binary Inputs

The ZN510 controller has three available binary inputs (BI). These inputs are factory-configured for the following functions:

z BI 1= Low temperature

detection (freezestat) (Circuit 2).

z BI 2 = Condensate overflow.

z BI 3 = Occupancy or generic

binary input.

Each binary input may be configured as not used depending on options selected. BI 3 is configured as a normally open occupancy input, but may be field modified for generic binary input which is only supported by a building automation system.

Note: The diagnostic functions related to binary inputs such as low temperature detection and condensate

overflow are fixed sequences.

Each binary input associates an input signal of 0 VAC with open contacts and 24 VAC with closed contacts. See Figure 6 for typical binary input configurations for the heat pump.

z Force compressor operation,

allowing the technician to use refrigerant gauges or other test equipment to verify unit operation.

The test sequence resets unit diagnostics and attempts to restore normal unit operation prior to testing the outputs. If the diagnostics remains after a reset, the status LED indicates the diagnostic condition is still present and has affected the

ZN510 does not use analog outputs.

Low Temperature Detection (Circuit 2)

Condensate Overflow

Field Wired Occupancy Input

J2-1

BI 1

J2-2

J2-3

BI 2BI 3

J2-4

J2-5

J2-6

Figure 6: Binary inputs.

Table 2: Binary input configurations

Binary Input Description

BI 1

BI 2 Condensate Overflow

BI 3

Low Temperature Detection (Cir 2)

Occupancy Normally open Unoccupied Occupied

Generic Normally open Normal Normal

manual output test. See Troubleshooting section for Green LED and Testing Heat Pump Configurations on page 21 & 22.

Binary Inputs

ConfigurationContact

Closure

Normally closed

Normal Diagnostic

Contact

Open

Note: See Page 10 for specific information concerning BI 1, BI 2 and BI 3.

Unit Operation

Low Temperature Detection

The low temperature detection

temperature condition exists for that circuit.

outdoor air damper also operates

normally. diagnostic protects the heat exchanger by using an analog leaving water temperature sensor to protect refrigerant circuit 1 and a binary low temperature detection device to protect refrigerant circuit

2. Each individual refrigerant circuit is disabled when the low

For two compressor units, the controller responds to low temperature detection by allowing the fan to operate, while disabling the compressor for the faulty circuit. The compressor for the normal circuit continues to operate. The

All unit operation is disabled when

the heat pump shuts down both

circuits, due to low temperature

conditions. See Table 3 for more

information.

Table 3: ZN510 response to low temperature detection diagnostic

Description

Low Temperature Detection

(Circuit 1)

Low Temperature Detection

(Circuit 2)

Low Temperature Detection

(Circuits 1 and 2)

Fan

Operation

Enabled

Disabled

Compressor Operation

Circuit 1-Disabled Circuit 2-Normal Operation

Circuit 1-Normal Operation Circuit 2-Disabled

Circuit 1-Disabled Circuit 2-Disabled

Damper

Operation

Normal operation

Closed

Note:

z The low temperature detection device automatically resets when the heat exchanger temperature returns to

normal. However, you must manually reset the low temperature detection diagnostic to clear the diagnostic and restart the unit. Refer to page 28 on how to reset a unit.

z If BOP 6 is configured as a generic binary output, the state of the output is not affected by the low temperature

detection diagnostic or by other diagnostics.

Condensate Overflow

A condensate overflow switch detects the condensate condition. The condensate overflow switch is a normally closed device. This switch is physically connected to the binary input 2 (BI 2). When the condensation reaches the trip point, the binary input detects the diagnostic condition. A condensate overflow signal generates a diagnostic which disables the fan, disables all compressors, and closes the 2-position outdoor air damper (when present). The condensate overflow diagnostic does not affect the generic binary output (when present).

Note: The condensate overflow switch, located in the condensate pan, automatically resets when the condensation returns to normal levels. However, you must manually reset the controller’s condensate overflow diagnostic to clear the diagnostic and restart the unit. Refer to page 28 on how to reset a unit.

Occupancy

ZN510 uses the occupancy binary input for two occupancy-related functions. For standalone controllers (any unit not receiving a communicated occupancy request, typically from a building automation

system), the occupancy binary input

determines the unit’s occupancy

based on the hardwired signal.

Typically, the signal is a dry set of

binary contacts which is either

connected to a switch or timeclock

contacts.

When a hardwired occupancy signal

is open, the unit switches to

occupied mode (if the occupancy

input is configured as normally

open). When a hardwired

occupancy signal is closed, the

controller switches to Unoccupied

mode.

+ 22 hidden pages

Trane Tracer, ZN510 User Manual

Table of Contents

Start-up Procedure

Power Up Sequence

Unit Operation