Trane Tracer ZN521 Installation And Operation Manual Download Page 1 | Manualshive

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SAFETY WARNING

Only qualified personnel should install and service the equipment. The installation, starting up, and servicing
of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and
training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or
serious injury. When working on the equipment, observe all precautions in the literature and on the tags,
stickers, and labels that are attached to the equipment.

November 2010

CNT-SVX07D-EN

Installation and
Operation

Tracer

™

ZN521 Zone Controller

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Summary of Contents for Tracer ZN521

Page 1: ...dous and requires specific knowledge and training Improperly installed adjusted or altered equipment by an unqualified person could result in death or serious injury When working on the equipment observe all precautions in the literature and on the tags stickers and labels that are attached to the equipment November 2010 CNT SVX07D EN Installation and Operation Tracer ZN521 Zone Controller ...

Page 2: ...of Trane in the United States and other countries All trademarks referenced in this document are the trademarks of their respective owners Warnings Cautions and Notices Warnings cautions and notices are provided in appropriate places throughout this document WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentia...

Page 3: ...unctions and wiring for typical applications 13 Binary inputs 13 BI1 Low coil temperature detection 14 BI2 Condensate overflow 14 BI3 Occupancy or generic binary input 14 BI4 Fan status 14 Analog inputs 14 GND Ground terminals 15 ZN Zone temperature 15 SET Local setpoint 15 FAN Fan mode input 15 AI1 Entering water temperature 16 AI2 Discharge air temperature 16 AI3 Outdoor air temperature or gener...

Page 4: ...e operation 36 Two pipe operation 37 Four pipe operation 37 Modulating outdoor return air dampers 37 ASHRAE Cycle 1 conformance 38 ASHRAE Cycle 2 conformance 38 Economizing free cooling 38 Two position control of a modulating outdoor air damper 39 Face and bypass damper operation 39 Face and bypass isolation valve operation 39 DX cooling operation 39 Electric heat operation 39 Baseboard heat opera...

Page 5: ...tus indicators for operation and communication 43 Test button 43 Manual output test 43 Service pin button 47 Interpreting LEDs 47 Diagnostics 48 Types of diagnostics 48 Table of diagnostics 49 Troubleshooting 51 Index 55 ...

Page 6: ...modulating or two position valves Tri state modulating dampers outdoor return air and face and bypass DX cooling single stage Electric heat two stages It is designed to be field installed and is sent from the factory unconfigured Use the PC based Rover service tool to configure the controller for specific applications Note For information about using the Rover service tool see the current version ...

Page 7: ...in 25 mm Top and bottom 4 0 in 102 mm Metal cover model see Figure 2 on page 8 Front 24 0 in 610 mm Each side 2 0 in 51 mm Top and bottom 1 0 in 25 mm Figure 1 Plastic cover model dimensions and clearances 4 in 102 mm 5 625 in 143 mm 1 in 25 mm 6 875 in 175 mm 1 in 25 mm 4 in 102 mm 4 in 102 mm 6 31 160 mm 2 in 51 mm 5 625 in 143 mm ...

Page 8: ...n These components are not included with the Tracer ZN521 zone controller Power transformer Use a UL listed Class 2 power transformer supplying a nominal 24 Vac 19 30 Vac to power both the Tracer ZN521 zone controller 14 VA and its associated output devices including relays and actuators to a maximum of 12 VA per output utilized Water duct and outdoor air temperature sensors Temperature sensors mu...

Page 9: ... a spring return as required by the application Damper actuators Damper actuators cannot exceed 12 VA draw at 24 Vac For control of outdoor return air dampers use tri state modulating actuators that incorporate a spring return Zone humidity sensor For measurement of relative humidity RH the Tracer ZN521 requires a zone humidity sensor with a 4 20 mA output where 4 mA is 0 RH and 20 mA is 100 RH Th...

Page 10: ...not exceed 300 ft 100 m Do not run input output wires in the same wire bundle with any ac power wires For application specific wiring information and diagrams see Input output functions and wiring for typical applications p 13 AC power wiring WARNING Hazardous Voltage Before making line voltage electrical connections lock open the supply power disconnect switch Failure to do so may cause death or ...

Page 11: ...cation link must meet the following requirements All wiring must comply with the National Electrical Code and local codes 22 AWG Level 4 unshielded communications wire recommended for most Comm5 installations Termination resistors are required for wiring LonTalk devices communicating on a network For specific information about using termination resistors for LonTalk applications refer to the Trace...

Page 12: ... the following requirements Temperature from 32 F to 140 F from 0 C to 60 C Relative humidity 5 95 noncondensing Mounting recommendations Mounting recommendations are as follows Notice Leave Controller Cover On Mount the Tracer ZN521 zone controller with the cover on to avoid the possibility of damaging the circuit board during installation Mount the controller in any position other than with the ...

Page 13: ...ion does not warrant the use of a particular input configure the input as Not Used This will disable the generation of diagnostics for this function Table 3 gives the function of each binary input Table 2 Typical applications for the Tracer ZN521 zone controller Application Multiple fan speed Dehumidification Auto minimum damper adjust Face and bypass damper Valve control Economizing Auxiliary bas...

Page 14: ...n of occupancy is to save energy by spreading zone setpoints when the zone is unoccupied As the occupancy input BI3 can be used for two related functions For stand alone controllers BI3 can be hard wired to a binary switch or timeclock to determine the occupancy mode either occupied or unoccupied For controllers receiving a BAS communicated occupancy request the function of BI3 is to change the mo...

Page 15: ...municated by means of a LonTalk link can also be used for controllers operating on a BAS If both hard wired and communicated setpoint values are present the controller uses the communicated value If neither a hard wired nor a communicated setpoint value is present the controller uses the stored default setpoints configurable using the Rover service tool If a valid hard wired or communicated setpoi...

Page 16: ...ature value is invalid or is not present the controller generates a Discharge Air Temp Failure diagnostic and shuts down the equipment When the thermistor returns to a valid temperature the controller automatically allows the equipment to resume normal operation Note AI2 is not polarity sensitive you can connect either terminal to either sensor lead AI3 Outdoor air temperature or generic temperatu...

Page 17: ...IP Failure diagnostic For the CO2 measurement configuration a 4 20 mA sensor must be hard wired to the AI4 terminal as shown in Figure 5 The sensor will transmit a 0 2000 ppm value to the BAS This configuration has no direct effect on Tracer ZN521 operation If a valid value is established and then is no longer present the controller generates a CO2 Sensor Failure diagnostic Figure 5 AI4 terminal w...

Page 18: ...mper The Tracer ZN521 controller includes ten binary outputs Each binary output is a triac with a rating of 12 VA at 24 Vac Table 6 describes the function of each output Tracer ZN521 RH sensor Table 6 Binary output functions Binary output Functions 1 Fan high 2 Fan medium Exhaust fan or damper 3 Fan low 4 Modulating cooling changeover valve open Two position cooling changeover valve DX cooling 5 M...

Page 19: ...The controller resets itself to normal operation after two hours Wiring requirements and options Table 7 shows required controller inputs for minimal proper operation of all applications Figure 7 p 20 through Figure 17 p 30 show typical applications that include all required and all optional components Table 7 Required controller inputs for proper operation Function Input source For more informati...

Page 20: ...speed Low coil temperature detection closed normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V Electric heat stage 1 optional out Fan status closed on 24 V Electric heat stage 2 optional 24 V Outdoor air damper actuator AI4 input See Figures Step 5 and Step 6 on p 18 for wiring options Discharge air temperature Open Close Open Close...

Page 21: ...Fan high speed Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V Heating valve out Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature Open Close Open Close Low coil temperature detection closed normal LonTalk All binary inputs are configurable Connect 24 V to an AC POWER 24V terminal AI4 input See Figures Step...

Page 22: ...mperature detection closed normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V Heating cooling changeover valve All binary inputs are configurable Connect 24 V to an AC POWER 24V terminal Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature 24 V Electric heat stage 1 optional 24 V Electric heat stage 2 opti...

Page 23: ...an high speed Low coil temperature detection open normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V Cooling valve out Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature 24 V Heating valve Open Close Open Close Open Close All binary inputs are configurable Connect 24 V to an AC POWER 24V terminal AI4 inp...

Page 24: ...tection closed normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V Heating cooling changeover valve out Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature 24 V Auxiliary heating valve Open Close Open Close Entering water temperature Open Close All binary inputs are configurable Connect 24 V to an AC POWER...

Page 25: ... Entering water temperature Outdoor air or generic temperature 24 V Exhaust or fan medium speed 24 V Fan low speed 24 V Fan high speed Low coil temperature detection closed normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V DX cooling out Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature 24 V Heating va...

Page 26: ...tering water temperature Outdoor air or generic temperature 24 V Exhaust 24 V Fan high speed Low coil temperaturedetection closed normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V DX cooling out Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature 24 V Electric heat stage 2 optional Open Close 24 V Electr...

Page 27: ...rature detection closed normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V Electric heat stage 1 out Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature 24 V Electric heat stage 2 Open Close All binary inputs are configurable Connect 24 V to an AC POWER 24V terminal AI4 input See Figures Step 5 and Step 6...

Page 28: ... speed Low coil temperature detection closed normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat out Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature 24 V Face bypass damper actuator Open Close Close Open 24 V Heat isolation valve open close All binary inputs are configurable Connect 24 V to an AC POWER 24V ...

Page 29: ...eed Low coil temperature detection closed normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V Heating cooling isolation valve open close out Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature 24 V Face and bypass damper actuator Open Close Open All binary inputs are configurable Connect 24 V to an AC POWE...

Page 30: ...perature detection closed normal Condensate overflow closed normal Occupancy open occupied LonTalk H N 24 Vac 24 V Generic baseboard heat 24 V Face and bypass damper actuator out Fan status closed on 24 V Outdoor air damper actuator Discharge air temperature 24 V Heating isolation valve open close Open Close Open 24 V Cooling isolation valve open close Close All binary inputs are configurable Conn...

Page 31: ...communicated occupancy request to arrive If a communicated occupancy request arrives normal operation can begin If a communicated occupancy request does not arrive the controller assumes stand alone operation 8 Normal operation begins assuming no diagnostics have been generated Random start Random start is intended to prevent all units in a building from energizing at the same time The random star...

Page 32: ...ed bypass mode The controller is placed in occupied bypass mode when the controller is operating in the unoccupied mode and either the timed override ON button on the Trane zone sensor is pressed or the controller receives a communicated occupied bypass signal from a BAS In occupied bypass mode the controller maintains the zone temperature based on the occupied heating or cooling setpoints The fan...

Page 33: ...d cooling capacity is at a minimum available heating capacity will be used to raise the discharge air temperature to the low limit see Discharge air tempering p 33 Simplified zone control In the unoccupied mode the controller maintains the zone temperature by calculating the required heating or cooling capacity 0 100 according to the measured zone temperature and the active zone temperature setpoi...

Page 34: ...ccupied cooling setpoint If economizing is possible the damper will open up above the minimum position Cool down can only happen once When the outdoor air damper gets to its minimum position morning cool down is over and cannot happen again until the next transition from unoccupied to occupied The controller will be in the occupied cooling mode when morning cool down is over Heating or cooling mod...

Page 35: ...tch is present the communicated value has priority Note In occupied mode The Tracer ZN521 zone controller requires continuous fan operation because of cascade zone control In unoccupied mode the fan cycles When the controller receives a communicated auto signal or the associated fan speed switch is set to AUTO with no communicated value present the fan will operate in the auto mode In the auto mod...

Page 36: ...geover with a single valve coil for two pipe applications The controller supports cooling or heat cool changeover with the main valve coil and heating only with the auxiliary valve coil for four pipe applications The controller moves the modulating valve to the desired positions based on heating or cooling requirements Modulating valve calibration Calibration of modulating valves is done automatic...

Page 37: ... four pipe applications Modulating outdoor return air dampers The Tracer ZN521 operates the modulating outdoor return air dampers according to the following factors Occupancy mode Outdoor air temperature communicated or hard wired sensor Zone temperature Setpoint Discharge air temperature Discharge air temperature setpoint The minimum position for an outdoor air damper is configurable using the Ro...

Page 38: ...nough to make this possible is referred to as economizing or free cooling Tracer ZN521 controller applications with modulating outside air damper support economizing The modulating outdoor air damper provides the first source of cooling for the Tracer ZN521 The controller initiates economizing if the outdoor air temperature is below the economizer enable point configurable using the Rover service ...

Page 39: ...ive condensate cooling mode from the coil In four pipe applications the isolation valves are used to prevent simultaneous heating and cooling The heating or cooling isolation valve opens whenever capacity is requested 0 as the face and bypass damper begins to modulate toward the coil face The isolation valve closes when capacity returns to 0 DX cooling operation The Tracer ZN521 supports one stage...

Page 40: ...ation is not available for face and bypass applications and cannot be used if the unit is in the unoccupied mode Dehumidification disables the economizing function Peer to peer communication Tracer ZN521 zone controllers have the ability to share data with other LonTalk based controllers Multiple controllers can be bound as peers using the Rover service tool to share Setpoint Zone temperature Heat...

Page 41: ...een operating normally for one minute but the fan status switch indicates no fan operation the same diagnostic is generated This manual diagnostic discontinues unit operation until the diagnostic has been cleared from the controller If a diagnostic reset is sent to the controller and the fan condition still exists the controller attempts to run the fan for 1 minutes before generating another diagn...

Page 42: ...d to analog input AI2 The freeze protection operation is initiated whenever the discharge air temperature falls below the Discharge Air Temperature Low Limit The Discharge Air Temperature Low Limit is configurable using the Rover service tool During freeze protection the controller increases the heating capacity or decreases the cooling capacity in order to raise the discharge air temperature abov...

Page 43: ...gure 19 Tracer ZN521 zone controller circuit board Manual output test The manual output test sequentially turns on and off all binary outputs to verify their operation The test overrides normal operation of the controller which is suspended while the test is being performed Use the manual output test to Verify output wiring and operation Force the water valve s open to balance the hydronic system ...

Page 44: ...en you press the Test button and then it blinks as described in Table 14 on page 47 when the Test button is released to indicate that the controller is in manual test mode 2 Press the Test button no more than once per second to advance through the test sequence Table 11 and Table 12 show the resulting activities of the binary outputs Note The outputs are not subject to minimum on or off times duri...

Page 45: ... Off On Close On Open Off Off Off Off 7 Aux open EH1 on exhaust fan5 On High 1 Off 2 On Off Off Off On Open Off Off Off Off 8 Aux close EH1 off EH2 on damper open On High Off Off Off Off Off On Close On Open Off Off 9 Damper close On High Off Off Off Off Off Off Off On Close Off 10 Generic baseboard heat energized6 On High Off Off Off Off Off Off Off Off On 11 Exit5 1 The controller turns off all ...

Page 46: ...x open EH1 on exhaust fan5 On High 1 Off 2 On Off Off On Open On Open Off Off Off Off 8 Aux close damper open On High Off Off Off Off Off On Close On Open Off Off 9 Outdoorair damper close On High Off Off Off Off Off On Close Off On Close Off 10 Generic baseboard heat energized6 On High Off Off Off Off Off On Close Off Off On 11 Exit5 1 The controller turns off all fan and electric heat outputs an...

Page 47: ...n power is applied to the controller The controller is operating normally LED is on continuously when power is applied to the controller The controller is not working properly or someone is pressing the Service pin button LED flashes once every second The controller is not executing the application software because the network connections and addressing have been removed 1 1 Restore the controller...

Page 48: ...ubleshooting p 51 Manual latching diagnostics Manual diagnostics also referred to as latching cause the unit to shut down Manual diagnostics can be cleared from the controller in one of the following ways By using the Rover service tool see Resetting a diagnostic in EMTX SVX01A EN Rover Installation Operation and Programming guide Through a building automation system see product literature By init...

Page 49: ...ass damper unaffected Informational Condensate Overflow The drain pan is full of water Fan off Valves closed Outdoor air damper closed Face and bypass damper bypass DX electric heat off Baseboard heat off Manual Low Coil Temp Detection The leaving fluid temperature may be close to freezing Fan off Valves open Outdoor air damper closed Face and bypass damper bypass DX electric heat off Baseboard he...

Page 50: ...fected Outdoor air damper unaffected Face and bypass damper unaffected DX cooling electric heat unaffected Baseboard heat unaffected Informational Local Fan Mode Failure Invalid or missing fan speed switch reverts to default fan speed Fan unaffected Valves unaffected Outdoor air damper unaffected Face and bypass damper unaffected DX cooling electric heat unaffected Baseboard heat unaffected Automa...

Page 51: ...nditions occurs 1 The controller exits power up control wait after it receives communicated information 2 The controller exits power up control wait after the power up control wait time expires Diagnostic present Several diagnostics affect fan operation For information about these diagnostics see Table 16 p 49 Unit configuration The controller must be properly configured based on the actual instal...

Page 52: ...art observed After power up the controller always observes a random start from 5 to 30 seconds The controller remains off until the random start time expires Requested mode off You can communicate a desired operating mode such as off heat and cool to the con troller If off is communicated to the controller the unit controls the fan off There is no heating or cooling Entering water temperature samp...

Page 53: ...iagnostic present Several diagnostics affect DX and electric heat operation For information about these diagnostics see Table 16 p 49 Normal operation The controller controls compressor or electric heat outputs as needed to meet the unit capacity requirements Unit configuration The controller must be properly configured based on the actual installed end devices and application If the unit configur...

Page 54: ...tdoor air damper closed during the transition from unoccupied to occupied This is an attempt to bring the space under control as quickly as possible Requested mode off You can communicate a desired operating mode such as off heat or cool to the control ler If off is communicated to the controller the unit closes the outdoor air damper Table 22 Outdoor air damper remains open Probable cause Explana...

Page 55: ...nsate overflow Diagnostic 49 Input 14 Switch 9 14 Configuration options AI3 Outdoor air temperature or generic 16 AI4 Generic CO2 measurement or RH measurement 17 BI3 Occupancy or generic 14 DX cooling 6 Electric heat 6 Face and bypass dampers 6 Outdoor return air dampers 6 Rover service tool 6 Tri state modulating dampers 6 Tri state modulating valves 6 Two position valves 6 Current sensing switc...

Page 56: ...onTalk communication Description 6 Termination resistors 11 Wiring and addressing 11 LonTalk protocol Emphasis see LonTalk communication Low coil temperature detection Diagnostic 14 49 Input 14 M Manual output test 43 Modulating outdoor return air dampers 37 Modulating valves Calibration 36 Operation 36 Morning cool down 34 Morning warm up 34 Mounting Cover 12 Diagram 12 Location 12 Operating envi...

Page 57: ...9 Freeze protection 9 14 Low coil temperature 9 Occupancy 9 14 T Temperature sensors Table of options 9 Water and duct 8 Zone 9 Termination resistors 11 Test button 43 44 Timeclock 14 Timed override control 32 Transformers 8 10 11 Troubleshooting DX cooling 53 Electric heat failure 53 Fans 51 Outdoor air damper 53 Valves 52 Two pipe operation 37 Two position damper control 39 Two position valve op...

Page 58: ... heating cooling unit with auto changeover 22 Two pipe hydronic cooling unit 20 Two pipe hydronic heating unit 21 Z Zone humidity Sensor 9 Zone temperature Input 15 Sensors 9 Zone temperature control 33 Zone temperature failure diagnostic 49 ...

Page 59: ......

Page 60: ... Trane offers a broad portfolio of advanced controls and HVAC systems comprehensive building services and parts For more information visit www Trane com Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice 2010 Trane All rights reserved CNT SVX07D EN 08 Nov 2010 Supersedes CNT SVX07C EN 01 Apr 2005 ...

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