Hardware Installation Tracer AH541 Version 2 Air-Handler ... · Tracer™ AH541 Version 2 Air-Handler Controller ... • Minimum clearances as shown in ... enclosure is mounted in

CNT-SVN02B-EN

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Hardware Installation

Tracer™ AH541 Version 2

Air-Handler Controller

®

Hardware Installation

Tracer™ AH541 Version 2

Air-Handler Controller

CNT-SVN02B-EN

February 2004

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CNT-SVN02B-EN

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CNT-SVN02B-EN

Tracer AH541 Version 2 Air-Handler Controller Hardware Installation

This guide and the information in it are the property of American Standard Inc. and may not be used or reproduced in whole or in part, without the written permission of American Standard Inc. Trane, a business of American Standard Inc., has a policy of continuous product and product data improvement and reserves the right to change design and specification without notice.

Although Trane has tested the system described in this guide, no guarantee is offered that the system is error free

Trane reserves the right to revise this publication at any time and to make changes to its content without obligation to notify any per-son of such revision or change.

Trane may have patents or patent applications covering items in this publication. By providing this document, Trane does not imply giving license to these patents.

The following are trademarks or registered trademarks of American Standard Inc.: Rover, Tracer, and Trane.

The following are trademarks or registered trademarks of their respective companies or organizations: LonMark and LonTalk from Echelon Corporation.

Printed in the U.S.A.

© 2004 American Standard Inc. All rights reserved.

™ ®

™ ®

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CNT-SVN02B-EN

NOTICE:Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully:

WARNINGIndicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

CAUTIONIndicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury.

It may also be used to alert against unsafe practices.

CAUTIONIndicates a situation that may result in equipment or property-damage-only accidents.

The following format and symbol conventions appear at appropriate sections throughout this manual:

IMPORTANTAlerts installer, servicer, or operator to potential actions that could cause the product or system to

operate improperly but will not likely result in potential for damage.

This symbol precedes a procedure that consists of only a single step.

Note:

A note may be used to make the reader aware of useful information, to clarify a point, or to describe options or alternatives.

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CNT-SVN02B-EN v

Contents

Chapter 1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Agency listing/compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Additional components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Power transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Operator display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Required tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection upon receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Tracer AH541 with enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Frame-mounted Tracer AH541 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Chapter 2 Installing the frame-mounted Tracer AH541 . . . . . 5

Enclosure requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installing the termination board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 3 Mounting the enclosure . . . . . . . . . . . . . . . . . . . . . 7

Selecting a mounting location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operating environment requirements . . . . . . . . . . . . . . . . . . . . . . . . 7

Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Mounting the enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 4 Wiring high-voltage ac power. . . . . . . . . . . . . . . . 11

Local power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Circuit requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Wiring high-voltage power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 5 Installing the pressure sensor . . . . . . . . . . . . . . . . 15

Installing the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Checking the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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vi CNT-SVN02B-EN

Chapter 6 Wiring inputs and outputs . . . . . . . . . . . . . . . . . . 19

Required inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Input/output wiring guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Wire routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Screw-terminal locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Binary outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Wiring binary outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Checking binary outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Wiring analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Checking analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Zone sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Wiring the zone sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Checking the zone sensor inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Wiring analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Checking the discharge-air and outside-air temperature inputs. . . 36

Checking the mixed-air temperature input . . . . . . . . . . . . . . . . . . . . 38

Wiring 4–20 mA analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Binary inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Wiring binary inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Checking binary inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chapter 7 Installing the circuit board . . . . . . . . . . . . . . . . . . 45

Chapter 8 Installing the door . . . . . . . . . . . . . . . . . . . . . . . . . 49

Installing the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Removing the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Chapter 9 Installing the stand-alone operator display. . . . . 51

Chapter 10 Connecting the portable operator display. . . . . . 55

Chapter 11 Setting up the operator display . . . . . . . . . . . . . . 57

Setting up time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Calibrating the operator display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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Contents

CNT-SVN02B-EN vii

Adjusting brightness and contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Chapter 11 Verifying operation and communication . . . . . . . 61

Test button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Performing a manual output test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Service Pin button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Interpreting LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Binary output LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Service LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Status LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Comm LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Interpreting diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Checking the earth ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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Contents

viii CNT-SVN02B-EN

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CNT-SVN02B-EN 1

Chapter 1

Overview

This guide shows how to install the Tracer AH541 air-handler controller.

Product descriptionThe Tracer AH541 air-handler controller is a low-cost, direct digital con-troller. It controls a wide variety of air-handlers and offers the following features:

• Factory programming of many unit configurations and sequences of operation simplifies installation and brings consistency to the air-handler controllers on a site

• Interoperability through Comm5 communications. (Comm5 is Trane’s implementation of LonTalk®.)

• Support of the LonMark® Space Comfort Controller (SCC) profile and the Discharge Air Controller (DAC) profile for air-handlers

• Operates as a stand-alone device, as part of a peer-to-peer network, or as part of a building automation system (BAS)

SpecificationsThe Tracer AH541 conforms to the specifications shown in Table 1.

Table 1. Tracer AH541 specifications

Dimensions(see Figure 5 on page 9 for dimensional drawing)

16 ½ in. × 14 ¾ in. × 5 ½ in.(418 mm × 373 mm × 140 mm)

Weight 15 lb (7 kg)

Operating temperature Without display: From –40°F to 158°F (–40°C to 70°C)With display: From 32°F to 122°F (0°C to 50°C)

Storage temperature Without display: From –40°F to 185°F (–40°C to 85°C)With display: From –13°F to 149°F (–25°C to 65°C)

Humidity 5–95% non-condensing

Altitude 6500 ft (2000 m)

Installation Category 3

Pollution Degree 2

High-voltage power requirements

North America: 98–132 Vac, 1 A maximum, 1 phaseOther: 196–264 Vac, 1 A maximum, 1 phase

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Chapter 1 Overview

2 CNT-SVN02B-EN

Agency listing/complianceUL and C-UL:

UL 916 Energy ManagementCUL C22.2 No. 205-M1985 Signal Devices

FCC:

CFR 47, Part 15, Subpart A, Class A

CE:

Emissions

EN55022 Class BEN61000-3-2EN61000-3-3

Immunity

EN50082-2 Industrial

Additional componentsThe Tracer AH541 controller requires additional components for certain applications and has several options for adding an operator display.

Power transformer

The frame-mounted Tracer AH541, which ships without an enclosure, requires a UL-listed Class 2 transformer providing 70 VA at 24 Vac.

Operator display

The operator display is available in three models (see Figure 1 on page 3):

• Door-mounted operator display• Stand-alone operator display, for mounting on a wall up to 150 ft

(46 m) from the controller• Portable operator display

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Required tools

CNT-SVN02B-EN 3

Figure 1. Operator display models

Required toolsTo install the Tracer AH541 controller and check it for proper operation, you will need the following tools:

• Drill• Phillips-head screwdriver• Small flat-tip screwdriver (for terminal screws)• Digital multi-meter

Door-mounted operator display Stand-alone operator display Portable operator display

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Chapter 1 Overview

4 CNT-SVN02B-EN

Inspection upon receiptMake sure that you have received the correct parts with your Tracer AH541 controller.

Tracer AH541 with enclosure

The Tracer AH541 with enclosure ships with:

• Enclosure with pre-mounted termination board• Main circuit board in a plastic frame• Enclosure door• Plastic bag containing four #10 (5 mm) wall anchors and four

#10 × 1.5 inch (5 × 40 mm) screws• Installation sheet

Frame-mounted Tracer AH541

The frame-mounted Tracer AH541 ships with:

• Termination board in a plastic frame• Main circuit board in a plastic frame• Installation sheet

Note:

The four #8 (4 mm) screws required to mount the frame-mounted Tracer AH541 are not supplied.

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CNT-SVN02B-EN 5

Chapter 2

Installing the frame-mounted

Tracer AH541

This chapter applies only to the frame-mounted Tracer AH541 controller. The frame-mounted Tracer AH541 can be used to replace older controllers in existing equipment or can be mounted in new equipment or custom enclosures.

Enclosure requirementsBefore installing the frame-mounted Tracer AH541, make sure that the enclosure or mounting space meets the following minimum requirements:

• Minimum clearances as shown in Figure 2• 24 Vac dedicated power supply• Compliance with National Electrical Code and applicable local elec-

trical codes for high-voltage power wiring to the enclosure

Figure 2. Frame-mounted Tracer AH541 minimum clearances

Note:

The Tracer AH541 with enclosure is mounted in a National Electrical Manufacturers Association (NEMA) 1 enclosure. To meet NEMA 4 specifications, you can order the frame-mounted Tracer AH541 (model BMTA000CA0A0) and mount it in a separately purchased NEMA 4 enclosure.

BO5

BO4

BO3

BO2

BO1

BO6

24VAC

AO4

AO3

AO6

AO5

AO2

IN3

IN2

IN1

AO1

IN6

IN7

IN5

IN11

IN12

IN10

IN9

IN8

IN4

½ in. (13 mm)

½ in. (13 mm)

3 in. (76 mm)for communications wires

6 in. (152 mm)for I/O wires

½ in. (13 mm)

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Chapter 2 Installing the frame-mounted Tracer AH541

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Installing the termination board

To install the termination board in a separately purchased enclo-

sure or in other equipment:

1. Remove the controller from its packaging and separate the top and bottom frames.

2. Using the bottom frame (with the termination board) as a template, mark the location of the four mounting holes on the mounting surface (see Figure 3).

Figure 3. Frame-mounted dimensions and mounting holes

3. Set the controller aside and drill holes for #8 (4 mm) screws at the marked locations.

4. Secure the controller to the mounting surface with #8 (4 mm) screws (not supplied).

To install input/output wires, the main circuit board, and other compo-nents, follow the instructions in the following chapters.

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CNT-SVN02B-EN 7

Chapter 3

Mounting the enclosure

This chapter describes location requirements and shows how to mount the Tracer AH541 enclosure.

Selecting a mounting locationMake sure that the location meets the operating environment require-ments and clearance requirements described in the following sections. The Tracer AH541 controller must be installed indoors. Trane recom-mends locating the controller:

• Near the controlled equipment to reduce wiring costs• Where service personnel have easy access• Where it is easy to see and interact with the operator display• Where public access is restricted to minimize the possibility of

tampering or vandalism

CAUTION

Avoid Equipment Damage!

Install the controller in a location that is out of direct sunlight. Failure to

do so may cause the controller to overheat.

Operating environment requirements

Make sure that the operating environment conforms to the specifications listed in Table 2.

Note:

The Tracer AH541 with enclosure is mounted in a National Electrical Manufacturers Association (NEMA) 1 enclosure. To meet NEMA 4 specifications, you can order the frame-mounted Tracer AH541 (model BMTA000CA0A0) and mount it in a separately purchased NEMA 4 enclosure.

Table 2. Operating environment specifications

Temperature Without display: From –40°F to 158°F (–40°C to 70°C)With display: From 32°F to 122°F (0°C to 50°C)

Humidity 5–95% non-condensing

High-voltage power

requirements

North America: 98–132 Vac, 1 A maximum, 1 phaseOther: 196–264 Vac, 1 A maximum, 1 phase

Weight Mounting surface must be able to support 25 lb (12 kg)

Altitude 6500 ft (2000 m)

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Chapter 3 Mounting the enclosure

8 CNT-SVN02B-EN

Clearances

Make sure that the mounting location has enough room to meet the mini-mum clearances shown in Figure 4. Figure 5 on page 9 shows the dimen-sions of the Tracer AH541 enclosure.

Figure 4. Minimum clearances for enclosure

24 in. (60 cm)to fully open door

12 in. (30 cm)

36 in. (90 cm)

12 in. (30 cm)50 in. (130 cm) recommended

12 in. (30 cm)

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Selecting a mounting location

CNT-SVN02B-EN 9

Figure 5. Tracer AH541 enclosure dimensions

Note:

Six of the twelve knockouts are dual-sized knockouts for 1-inch (25 mm) and ¾-inch (19 mm) conduit.

Front

Top

Bottom

Left

Right

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Chapter 3 Mounting the enclosure

10 CNT-SVN02B-EN

Mounting the enclosure

To mount the enclosure:

1. Using the enclosure as a template, mark the location of the four mounting holes on the mounting surface (see Figure 6).

Figure 6. Enclosure mounting holes

2. Set the enclosure aside and drill holes for the screws at the marked locations.

Drill holes for #10 (5 mm) screws or #10 wall anchors. Use wall anchors if the mounting surface is dry wall or masonry.

3. Insert wall anchors if needed.

4. Secure the enclosure to the mounting surface with the supplied#10 (5 mm) screws.

Mounting hole (four locations)

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CNT-SVN02B-EN 11

Chapter 4

Wiring high-voltage ac power

This chapter shows how to wire high-voltage ac power to the enclosure.

Local power requirementsThe Tracer AH541 controller is available in five configurations, described in Table 3. Before wiring high-voltage power, make sure that you have the correct model for local power requirements. You can find the model num-ber on the shipping label or on the product label inside the enclosure.

Circuit requirementsTo ensure proper operation of the Tracer AH541, install the power supply circuit in accordance with the following guidelines:

• The Tracer AH541 must receive high-voltage power from a dedicated power circuit. Failure to comply may cause control malfunctions.

• A disconnect switch for the dedicated power circuit must be near the controller, within easy reach of the operator, and marked as the dis-connecting device for the controller.

• High-voltage power-wire conduits or wire bundles must not contain input/output wires nor the operator display cable connected to conrol-ler. Failure to comply may cause the controller to malfunction due to electrical noise.

Table 3. Tracer AH541 models

Model Number Description

BMTA000AA0A0 Enclosure, 120 Vac

BMTA000AA0A1 Enclosure, 120 Vac, with operator display

BMTA000BA0A0 Enclosure, 230 Vac, CE-compliant

BMTA000BA0A1 Enclosure, 230 Vac, with operator display, CE-compliant

BMTA000CA0A0 Frame-mounted, 24 Vac, CE-compliant

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Chapter 4 Wiring high-voltage ac power

12 CNT-SVN02B-EN

• High-voltage power wiring must comply with the National Electrical Code (NEC) and applicable local electrical codes.

• High-voltage power wiring requires three-wire 120/230 Vac service (line, neutral, ground). Use copper conductors only.

Wiring high-voltage power

WARNING

Hazardous Voltage!

Before making electrical connections, lock open the supply-power dis-

connect switch. Failure to do so may cause death or serious injury.

CAUTION

Use Copper Conductors Only!

Unit terminals are designed to accept copper conductors only. Other

conductors may cause equipment damage.

IMPORTANTMake sure that you have the correct Tracer AH541 model for 120 Vac or

230 Vac. Table 3 on page 11 lists the available models.

To connect high-voltage power wires:

1. Lock open the supply-power disconnect switch.

2. At the top right corner of the enclosure, remove the knockout and install ½-inch (13 mm) conduit (see Figure 7).

Note:

The voltage utilization range for the Tracer AH541 transformer is 98–132 Vac (120 Vac nominal) or 196–264 Vac (230 Vac nomi-nal). The panel detects whether the current is 50 or 60 cycle.

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Wiring high-voltage power

CNT-SVN02B-EN 13

Figure 7. Knockout for high-voltage power wires

3. Open or remove the Tracer AH541 door if it is already installed (see Chapter 8, “Installing the door”).

4. Inside of the enclosure at the top-right corner, remove the high-volt-age area cover plate.

5. Feed the high-voltage power wires into the enclosure.

6. Connect the line wire to the L terminal as shown in Figure 8.

Figure 8. Terminal block for high-voltage power wires

7. Connect the neutral wire to the N terminal.

Power wire entry throughknockout for ½-inch conduit

Ground wire toground screw

Line wire to L terminalNeutral wire to N terminal

Conduit

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Chapter 4 Wiring high-voltage ac power

14 CNT-SVN02B-EN

8. Connect the green ground wire to the chassis ground screw. The ground wire should be continuous back to the circuit-breaker panel.

9. Replace the cover plate.

WARNING

Hazardous Voltage!

The cover plate must be in place when the controller is operating. Fail-

ure to replace the cover plate could result in death or serious injury.

10. On a label, record the location of the circuit-breaker panel and the electrical circuit. Attach the label to the cover plate.

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CNT-SVN02B-EN 15

Chapter 5

Installing the pressure sensor

This chapter shows how to install a pressure sensor in the Tracer AH541 controller. The pressure sensor available for the Tracer AH541 is a 5 Vdc, 0–5 inches water column, differential pressure sensor. To simplify instal-lation of the pressure sensor, mount and wire it before wiring the other inputs and outputs.

IMPORTANTWhen configured for variable-air-volume control, the Tracer AH541 con-

troller must receive a valid duct static-pressure value to operate prop-

erly. The duct static-pressure value may be communicated over the

Comm5 network or wired directly to the controller.

The controller does not require a duct static-pressure value for constant-volume space-temperature control or constant-volume discharge-air tem-perature control.

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Chapter 5 Installing the pressure sensor

16 CNT-SVN02B-EN


IMPORTANTUse only pressure sensors with non-conductive plastic cases with the

Tracer AH541 controller. Pressure sensors with conductive plastic cases

may generate incorrect data. To ensure proper results, order the Trane

pressure-differential 5 Vdc sensor kit (part number 4020 1159).

To mount the pressure sensor in the Tracer AH541 enclosure:

1. Open the enclosure door.

2. Use the supplied #6 (3.5 mm) mounting screws to mount the pressure sensor to the mounting holes shown in Figure 9.

Figure 9. Mounting the pressure sensor

3. Connect the pressure-sensor cable to the duct static connector on the termination board as shown in Figure 10.

The duct static connector is keyed. If you have difficulty connecting the cable, rotate it 180° and try again.

4. Run the high and low input tubes to an appropriate place in the duct.

Pressure sensor mounting holes

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CNT-SVN02B-EN 17

Figure 10. Wiring the pressure sensor

Duct static connector

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Chapter 5 Installing the pressure sensor

18 CNT-SVN02B-EN

Checking the pressure sensorYou can check the pressure sensor for proper operation only after supply-ing power to the controller and installing the main circuit board. You will need a digital multi-meter to complete the check.

To check the pressure sensor for proper operation:

1. Make sure that the main circuit board has been installed and power has been provided to the controller.

2. Make sure that the pressure-sensor is connected to the duct static input on the termination board.

3. Set the digital multi-meter to measure dc voltage.

4. Connect the multi-meter to the input as shown in Figure 11 and dis-cussed in table Table 4.

Figure 11. Connecting the multi-meter to the duct static input

5. Make sure that the multi-meter readings fall within the ranges shown in Table 4. If a reading is not within the expected range, check for faulty connections or a faulty pressure sensor.

For additional troubleshooting information, refer to the Tracer AH540 user guide, CNT-SVX05B-EN.

Table 4. Expected voltages for the pressure sensor input

Multi-meter (–) lead at Multi-meter (+) lead at Measured dc voltage

Green (ground) Red (in) 4.8–5.2 Vdc

Green (ground) Black (out) 0.24–5.42 Vdc

Duct static connectoron termination board

GreenBlack

Red

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CNT-SVN02B-EN 19

Chapter 6

Wiring inputs and outputs

This chapter shows how to wire and test Tracer AH541 inputs and out-puts. Table 5 and Table 6 describe the inputs and outputs. Each input screw-terminal on the termination board has a specific function. For example, an outside-air temperature sensor can be connected only to ter-minal IN5. Note that the Tracer AH541 does not use AO6. For additional information on inputs and outputs, refer to the Tracer AH540 user guide, CNT-SVX05B-EN.

Table 5. Inputs

Input Type Function Sensor type Range

IN1 Analog Space temp 10 kΩ thermistor 5° to 122°F (–15° to 50°C)

IN2 Analog Space setpoint 1 kΩ potentiometer 50° to 85°F (10° to 29.4°C)

IN3 Analog Fan-mode switch Switched resistance Off (4870 Ω ±5%), Auto (2320 Ω ±5%)

IN4 Analog Discharge-air temp 10 kΩ thermistor –40° to 212°F (–40° to 100°C)

IN5 Analog Outdoor air temp 10 kΩ thermistor –40° to 212°F (–40° to 100°C)

IN6 Analog Mixed-air temp RTD 1 –40° to 212°F (–40° to 100°C)

IN7 Binary Low temp detect or defrost — —

IN8 Binary Run/stop — —

IN9 Binary Occupancy or generic — —

IN10 Binary Supply fan status — —

IN11 Binary Filter status — —

IN12 Binary Exhaust fan status or defrost — —

IN13 Analog Space relative humidityCO2 sensorEntering water temperatureEvaporator refrigerant tempGeneric temperature

Current: 4 to 20mACurrent: 4 to 20mAThermistorThermistorThermistor

0 to 100%0 to 2000 ppm-40 to 212°F (-40 to 100°C)-40 to 212°F (-40 to 100°C)-40 to 212°F (-40 to 100°C)

1 Resistance temperature detector (RTD), 1000 Ω at 32°F (0°C), 385 platinum curve.

Table 6. Outputs

Output Function Maximum output rating

AO1 Supply fan speed 20 mA

AO2 Cool output 20 mA

AO3 Heat output 20 mA

AO4 Face and bypass damper 20 mA

AO5 Outdoor air damper 20 mA

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Chapter 6 Wiring inputs and outputs

20 CNT-SVN02B-EN

Required inputsThe Tracer AH541 must receive some values to function properly. These values can be supplied from hard-wired connections to the controller or from network variables communicated over a Comm5 link. Table 7 lists the required inputs and the configurations for which they are required.

AO6 Not used —

BO1 Supply fan start/stop 12 VA

BO2 Exhaust fan start/stop 12 VA

BO3 DX stage 1 or Electric heat stage 4

12 VA


12 VA


12 VA


12 VA

Table 7. Required inputs

Required input Control function Required for

Discharge-air temperature

Discharge-air temperature control and space temperature control

All configurations

Space temperature Space temperature control SCC configuration

Outside-air temperature

Economizer control SCC or DAC configuration 1

Mixed-air temperature

Economizer control SCC or DAC configuration 1

Duct static-pressure

Variable-air-volume control DAC configuration

Space relative humidity

Space Dehumidification SCC configurations 1

Entering water temperature

2-pipe changeover SCC configurations 1

1 A communicated value will allow this function to operate without a locally wired sensor.

Table 6. Outputs (Continued)

Output Function Maximum output rating

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Required tools

CNT-SVN02B-EN 21

Required toolsTo wire inputs and outputs and check them for proper operation, you will need the following tools:

• Small flat-tip screwdriver• Digital multi-meter

Input/output wiring guidelinesInput/output wiring must meet the following guidelines:

• Wiring must conform with the National Electrical Code and local elec-trical codes.

• Use only 18–22 AWG (1.02–0.643 mm2), twisted-pair wire with stranded, tinned-copper conductors.

• Binary input/output wires must not exceed 1,000 ft (300 m).• Analog input wires must not exceed 300 ft (100 m) for thermistors

and 0–10 Vdc inputs and 1,000 ft (300 m) for 0–20 mA inputs.• Analog output wires must not exceed 1,000 ft (300 m) for 0–10 Vdc

outputs and 0–20 mA outputs.• Do not run input/output wires in the same wire bundle with high-

voltage power wires. Running input/output wires with 24 Vac power wires is acceptable, but the input wire must be shielded.

• Terminate input/output wires before installing the main circuit board (see Chapter 7, “Installing the circuit board”).

Wire routingFigure 12 on page 22 shows how to route input/output wires through the enclosure. It also shows the locations of wire-tie brackets. See Figure 5 on page 9 for knockout locations and dimensions. Metal conduit may be required by local codes when running input/output wires.

Note:

If your application requires a pressure sensor, install the pressure sensor before wiring other inputs and outputs. For more information, refer to Chapter 5, “Installing the pressure sensor.”

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22 CNT-SVN02B-EN

Figure 12. Wire routing

Brackets for wire ties (9 locations)

Pressure sensor will affect wire routing

Recommended communication wire route

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Screw-terminal locations

CNT-SVN02B-EN 23

Screw-terminal locationsFigure 13 on page 24 shows the location of the screw-terminals on the ter-mination board. The top row of screw terminals is for signal wires, and the bottom row of screw terminals is for common wires. To make sure that the wires lie flat, use the wire strip guide on the termination board to strip input/output wires to the correct length.

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24 CNT-SVN02B-EN

Figure 13. Screw-terminal locations

Common terminalsSignal terminals

Comm5 terminalsJack for Rover service tool

Not usedDuct static pressure connector

BO1 Supply fan start/stopBO2 Exhaust fan start/stop

AO1 Supply fan speedAO2 Cool outputAO3 Heat output

AO4 Face and bypass damperAO5 Outdoor air damper

IN1 Space tempIN2 Space setpoint

IN3 Fan-mode switchIN4 Discharge-air temp

IN5 Outdoor air temp

IN7 Low temp detect

IN6 Mixed-air temp

IN8 Run/stopIN9 Occupancy (or generic)

IN10 Supply fan statusIN11 Filter status

IN12 Exhaust fan status

Termination board Main circuit board

BO3 DX stage 1 or Elec. heat stage 4BO4 DX stage 2 or Elec. heat stage 3BO5 DX stage 3 or Elec. heat stage 2BO6 DX stage 4 or Elec. heat stage 1

IN13 Space relative humidity, CO2 sensor, entering water temperature, or evaporator refrigerant temp

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Binary outputs

CNT-SVN02B-EN 25

Binary outputsThe Tracer AH541 controller has six binary outputs that are normally-open, form-A binary relays. The relays act as a switch by either complet-ing or breaking the circuit between the load (the end device) and the 24 Vac power. For example, when binary output 1 is energized, 24 Vac is supplied to terminal BO1, which in turn energizes the supply fan start/stop relay.

Figure 14. Binary output schematic

Supply fan start/stop relay

24 VacTermination board

GND

Wiring external to the termination board

BO1

GND

Note:

The devices connected to terminals BO1, BO2, BO3, BO4, BO5, and BO6 can be either powered outputs or pilot relays. Figure 15 on page 26 shows an example of each.

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26 CNT-SVN02B-EN

Wiring binary outputs

IMPORTANTUse pilot relays for dry-contact outputs and when the load current is

greater than 0.5 A. Use powered outputs when the load current is less

than 0.5 A.

To wire a binary output:

1. Connect the common wire to a common terminal as shown in Figure 15.

2. Connect the shield wire to a common terminal at the termination board and tape it back at the output device.

3. Connect the signal wire to the appropriate binary output terminal (BO1 for supply fan, BO2 for exhaust fan, and BO3–BO6 for DX or electric heat).

4. Use the Rover service tool to configure the binary output.

Figure 15. Wiring binary outputs

Note:

When controlling coil-based loads, such as pilot relays, do not forget to account for “inrush” current. Inrush current can be three (or more) times greater than the operating current. You can find information on inrush current for specific types of out-puts in their product specifications.

Note:

Because the common terminals are in parallel, you can wire the common wire to any available common terminal.

< 1000 ft(300 m)

< 1000 ft(300 m)

Pilot relay24 Vac coil

Signal

Common

Signal

Common

Tape back shield

Powered output

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Binary outputs

CNT-SVN02B-EN 27

Checking binary outputs

IMPORTANTPerform the tests in this section before providing power to the termina-

tion board or installing the main circuit board. Failure to do so will

result in incorrect multi-meter readings.

To check binary outputs for proper operation:

1. Set a digital multi-meter to measure Vac, then measure the voltage across the binary output at the common and signal screw terminals.

The measured voltage should be less than 0.1 Vac. If the voltage is greater than this, the load may turn on and off unexpectedly. Check for the following problems:

• A shared power supply may be incorrectly connected. Check the wire to make sure that no additional connections have been made.

• The wire may have an induced voltage somewhere along its length.

2. Set the multi-meter to measure Vdc, then measure the voltage across the binary output at the common and signal screw terminals.

The measured voltage should be less than 0.1 Vdc. If the it is greater than this, a shared power supply may be incorrectly connected. Check the wire to make sure that no additional connections have been made.

CAUTION


Continue to step 3 only if you completed steps 1 and 2 successfully.

Measuring resistance may damage the meter if the voltage is too high.

3. Set the multi-meter to measure resistance. If you completed steps 1 and 2 successfully, measure the resistance across the binary output to confirm that there are no shorts and no open circuits.

Resistance is load dependent. Pilot relays have a relatively low resis-tance of less than 1 kΩ , but some actuators have a high resistance. Check to see what kind of binary output is connected before checking for open and short circuits.


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28 CNT-SVN02B-EN

Analog outputsThe Tracer AH541 controller has five 0–10 Vdc analog outputs. Analog outputs control actuators and secondary controllers.

Wiring analog outputs

To wire an analog output:

1. Connect the common wire (if applicable) and shield wire to a common terminal at the termination board (see Figure 16).

2. Tape the shield wire back at the output device.

3. Connect the signal wire to the appropriate analog output terminal (see Figure 13 on page 24).

4. Connect the supply wire to a 24 Vac terminal as required.

5. Use the Rover service tool to configure the analog output.

Figure 16. Example of wiring analog outputs

0–10 Vdc outputLoad > 500 Ω

< 1000 ft(300 m)

Ac powered actuator

Signal

Common

24 Vac

Signal

Common

Tape back shield

Tape back shield

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Analog outputs

CNT-SVN02B-EN 29

Checking analog outputs




To check 0–10 Vdc analog outputs for proper operation:

1. Make sure that the actuator is connected but powered off.

2. Set a digital multi-meter to measure Vac, then measure the voltage across the analog output at the signal and common screw terminals.

The measured voltage should be less than 0.1 Vac. If the voltage is greater than this, the load may turn on and off unexpectedly. Check for the following problems:

• A shared power supply may be incorrectly connected. Check along the wire to make sure that no additional connections have been made.

• The wire may have an induced voltage somewhere along its length.

3. Set the multi-meter to measure Vdc, then measure the voltage across the analog output at the signal and common screw terminals.

The measured voltage should be less than 0.1 Vdc. If the voltage is greater than this, a shared power supply may be incorrectly con-nected. Check along the wire to make sure that no additional connec-tions have been made.

CAUTION




4. Set the multi-meter to measure resistance. If you completed steps 2 and 3 successfully, measure the resistance across the analog output at the signal and common screw terminals.

The resistance should be greater than 500 Ω . (The analog output will not be able to reach 10 Vdc if the load resistance is less than 500 Ω .)


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30 CNT-SVN02B-EN

Zone sensorThe Tracer AH541 controller supports the Trane zone temperature sen-sors listed in Table 8.

Zone sensors can provide the following inputs to the Tracer AH541:

• Space temperature (IN1)• On and Cancel requests (IN1)• Local setpoint (IN2)• Fan-mode switch (IN3)• Communication jack for the Rover service tool• Service pin request

Typically, zone sensors are wall-mounted in the controlled space. Zone sensors use a 10 kΩ thermistor to measure the space temperature. The space temperature input can also provide On/Cancel requests to the con-troller. When a user presses the On or Cancel button, the signal is tempo-rarily interrupted, which the Tracer AH541 interprets as an On or Cancel request.

Zone sensors may have a setpoint-adjustment thumbwheel to configure a local setpoint. Hard-wire the local setpoint to the controller through the IN2 terminal. Use the Rover service tool to enable or disable the local set-point.

The fan mode input provides specific resistances for each position of the fan-mode switch. The controller interprets the resistance to determine the requested fan mode (Auto or Off). Use the Rover service tool to enable or disable the fan-mode switch. If the switch is disabled, the controller defaults to the Auto fan mode.

Some zone sensor models have an RJ-11 communication jack for the Rover service tool. When the communication jack is wired to the control-ler, you can use Rover to configure other Comm5 controllers on the link.

A service pin request identifies the controller in the Rover service tool. This is useful to make sure that you are configuring the correct device in Rover. To send a service pin request, press the On button for ten seconds.

Table 8. Tracer zone temperature sensor options

BAS part number

Fan switch Zone Override buttons

Comm jack

Auto Off Setpoint thumbwheel

Temperature sensor

On Cancel

4190 1087 x

4190 1088 x x x x

4190 1090 x x x x x

4190 1094 x x x

4190 1117 x x x x x x x

Note: The Tracer AH541 can support zone sensors with High, Med, and Low switch positions, but interprets these as Auto.

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Zone sensor

CNT-SVN02B-EN 31

Wiring the zone sensor

Table 9 describes the screw terminals on Trane zone sensors. Terminal 1 is the bottom terminal and terminal 6 is the top terminal.

To wire the zone sensor:

1. Connect the common wire to a common terminal.

2. Connect the space temperature signal wire to the IN1 terminal (see Figure 17).

3. Connect the space setpoint signal wire to the IN2 terminal.

4. If the zone sensor has a fan-mode switch, connect the fan mode signal wire to the IN3 terminal.

5. Use the Rover service tool to configure the zone sensor.

Figure 17. Wiring the zone sensor

Table 9. Screw terminals on a zone sensor

TerminalZone sensor

with fan-mode switchZone sensor

without fan-mode switch

1 Space temperature Space temperature

2 Common Common

3 Setpoint Setpoint

4 Fan mode Communications 1

5 Communications 1 Communications 1

6 Communications 1 Not present1 Do not connect if Comm5 communications are not required at the zone sensor.

Fan modeSetpointCommonSpace temp < 300 ft

(100 m)

Trane zone sensor

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32 CNT-SVN02B-EN

Checking the zone sensor inputs




To check the space temperature input (IN1), refer to the instructions in “Checking the discharge-air and outside-air temperature inputs” on page 36.

To check the setpoint (IN2) and fan mode (IN3) inputs:

1. Make sure that the sensor is connected.

2. Set a digital multi-meter to measure Vac, then measure the voltage across the input at the signal and common screw terminals.

The measured voltage should be less than 0.1 Vac. If the voltage is greater than this, resistance readings may change erratically.

3. Set the multi-meter to measure Vdc, then measure the voltage across the input at the signal and common screw terminals.

The measured voltage should be less than 0.1 Vdc. If the voltage is greater than this, resistance readings may be offset.

CAUTION




4. Set the multi-meter to measure resistance. If you completed steps 2 and 3 successfully, measure the resistance across the input at the sig-nal and common screw terminals.

For the setpoint input (IN2), the resistance should be between 100 Ω and 900 Ω . For the fan mode input (IN3), the resistance should be either 4.9 kΩ (Off) or 2.3 kΩ. (Auto).

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Analog inputs

CNT-SVN02B-EN 33

Analog inputsAnalog inputs provided by the zone sensor are discussed in “Zone sensor” on page 30. The remaining analog inputs are:

• Discharge-air temperature (IN4, 10 kΩ thermistor)• Outdoor air temperature (IN5, 10 kΩ thermistor)• Mixed-air temperature (IN6, RTD)• Universal Analog Input (IN13)

• Space relative humidity (current, 4 to 20mA)• CO2 sensor (current, 4 to 20mA)• Entering water temperature (10 kΩ thermistor)• Evaporator refrigerant temperature (10 kΩ thermistor)• Generic temperature (10 kΩ thermistor)

IMPORTANTThe Tracer AH541 controller must receive a valid discharge-air tempera-

ture value to operate properly for all control modes. The sensor must be

located at the discharge point downstream from all unit heating/cool-

ing capacity.

The discharge-air temperature sensor must be a 10 kΩ thermistor (see Table 10 for Trane part numbers).

The controller uses the outdoor air temperature input to determine if economizing (using outdoor air for free cooling) is feasible. The controller also uses the input to determine if it should enter freeze avoidance mode when the supply fan is off. The outdoor air temperature sensor must be a 10 kΩ thermistor.

The Tracer AH541 can accept a mixed-air temperature value only from a 385 platinum resistance temperature detector (RTD). The controller uses the mixed-air temperature input for mixed-air tempering and economiz-ing operations. Economizing cannot be performed without a valid outdoor air temperature and mixed-air temperature.

The Tracer AH541 has a universal analog input that can be configured using the Rover service tool for five purposes; space relative humidity, CO2 sensor input, entering water temperature, evaporator refrigerant temperature and generic temperature. The controller requires a space relative humidity input (locally wired or communicated value) for dehu-midification control in SCC applications. Also an entering water temper-ature sensor is required for 2-pipe auto changeover and entering water sampling function for air handling equipment with one hydronic changeover coil. When the universal analog input is configured for evap-orator refrigerant temperature the controller will use the sensor for detecting DX coil frost conditions. Low refrigerant temperatures on the suction line will cause the AH540 to reduce DX cooling capacity until refrigerant temperatures rise to normal operating temperatures.

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34 CNT-SVN02B-EN

If the universal analog input is configured for CO2 sensor input or generic temperature, the controller will not use the input for any control purposes and passes the input data to the building automation system.

You can use the sensors described in Table 10.

Table 10. Sensors available from Trane

Purpose Part number Sensor type

Discharge-air temperature

4190 11034190 11104190 1111

4-inch thermistor6-inch thermistor12-inch thermistor

Outdoor-air temperature

4190 1101 Thermistor

Mixed-air temperature 4190 1119 385 platinum 24-foot duct-aver-aging RTD

Space relative humidity

4190 7018 5% Room relative humidity (4 to 20 mA) & temperature sensor (thermistor)

CO2 sensor 4190 41004190 4101

Current, 4 to 20 mA, wall mountCurrent, 4 to 20 mA, duct mount

Entering water temperature

X39640722-01 Thermistor

DX coil defrost sensor X39640722-01 Installation kit: Thermostat/ther-mistor suction line installation.

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Analog inputs

CNT-SVN02B-EN 35

Wiring analog inputs

To wire the discharge-air temperature input, the outside-air tem-

perature input, and the mixed-air temperature input:

1. Connect the common wire to a common terminal as shown in Figure 18.

2. Connect the shield wire to a common terminal at the termination board and tape it back at the sensor.

3. Connect the signal wire to the appropriate input terminal (see Figure 13 on page 24).

Figure 18. Wiring variable resistance analog inputs

T

Variable resistance

Temperature sensor

< 300 ft(100 m)

Signal

Common

Signal

Common Tape back shield

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36 CNT-SVN02B-EN

Checking the discharge-air and outside-air temperature

inputs




To check the discharge-air and outside-air temperature inputs for

proper operation:



The measured voltage should be less than 0.1 Vac. If the voltage is greater than this, temperature readings may change erratically.


The measured voltage should be 0 Vdc. If the voltage is greater than this, temperature readings may be offset from the expected results.

CAUTION





The resistance should be between 325 kΩ and 700 Ω, which translates to temperatures of –40°F and 210°F (–40°C and 100°C). Specific tem-peratures and resistances are shown in Table 11 on page 37.

®

Analog inputs

CNT-SVN02B-EN 37


Table 11. Temperature and resistance characteristics of sensors

Temperature(°F and °C)

Thermistor resistance (Ω)for outdoor air temp and

discharge-air temp

385 platinum RTD resistance (Ω)

for mixed-air temp

–40°F (–40°C) 325,000 844

–30°F (–34°C) 241,071 865

–20°F (–29°C) 170,041 886

–10°F (–23°C) 121,326 908

0°F (–18°C) 87,511 930

10°F (–12°C) 63,769 952

20°F (–7°C) 46,919 974

30°F (–1°C) 34,839 996

40°F (4°C) 26,221 1,017

50°F (10°C) 19,955 1,039

60°F (16°C) 15,333 1,061

70°F (21°C) 11,889 1,082

80°F (27°C) 9,298 1,104

90°F (32°C) 7,330 1,125

100°F (38°C) 5,824 1,147

125°F (52°C) 3,382 1,200

150°F (66°C) 2,049 1,254

175°F (79°C) 1,296 1,307

200°F (93°C) 837 1,360

210°F (100°C) 700 1,381

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38 CNT-SVN02B-EN

Checking the mixed-air temperature input




To check the mixed-air temperature input for proper operation:



The measured voltage should be less than 0.1 Vac. If the voltage is greater than this, temperature readings may change erratically.


The measured voltage should be less than 0.1 Vdc. If the voltage is greater than this, temperature readings may be offset.

CAUTION





For a 385 platinum RTD, the resistance should be between 844 Ω and 1,381 Ω, which translates to temperatures of –40°F and 210°F (–40°C and 100°C). Table 11 on page 37 shows the resistance for various tem-peratures within this range.


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Analog inputs

CNT-SVN02B-EN 39

Wiring 4–20 mA analog inputs

4–20 mA analog inputs include humidity sensors and CO2 sensors.

To wire a 4–20 mA analog input:

1. Connect the common wire (if applicable) and shield wire to the GND terminal at IN13.

2. Tape the shield wire back at the sensor.

3. Connect the signal wire to IN13.

4. Connect the supply wire to a 24 Vdc or 24 Vac terminal as required.

5. Use the Rover service tool to configure the input for analog operation.

Note:

This connection is made at IN13, which is located on the main circuit board. The main circuit board must be installed before you can wire the 4–20 mA analog inputs. See Chapter 7, “Installing the circuit board” for details.

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40 CNT-SVN02B-EN

Figure 19. Wiring 4–20 mA analog inputs

i

i

IN3

IN2

IN1

IN6

IN7

IN5

IN11

IN12

IN10

IN9

IN8

IN4

IN3

IN2

IN1

IN6

IN7

IN5

IN11

IN12

IN10

IN9

IN8

IN4

24 Vdc

4–20 mA out

Common

< 1000 ft(300 m)

< 1000 ft(300 m)

4–20 mA sensor(current source)

24 Vdc

4–20 mA out

4–20 mA sensor(current controller)

Tape back shield

Tape back shield

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Binary inputs

CNT-SVN02B-EN 41

Binary inputsBinary inputs are used to monitor statuses, such as fan status and filter status. You must use the Rover service tool to configure binary inputs for the Tracer AH541. Configure binary inputs that are not in use as Not Used.

The binary inputs to the Tracer AH541 are:

• Low temperature detection—freezestat or DX Coil defrost (IN7)• Run/stop (IN8)• Occupancy or generic (IN9)• Supply fan status (IN10)• Filter status (IN11)• Exhaust fan status or DX Coil defrost (IN12)

Table 12 describes the configuration of Tracer AH541 binary inputs.

Low temperature detection protects the coils of hydronic units. A low tem-perature detection device (freezestat) detects when the temperature becomes too low (Trane part number 4190 1084). When the controller receives a low temperature signal, it generates a Low Temperature Detect diagnostic, which disables the fan, opens all water valves, and closes the outdoor air damper if one is present. You can reset the low temperature detection device automatically or manually. However, you must reset the Tracer AH541 controller manually to clear the diagnostic and restart the unit.

The run/stop binary input can shut down the controller based on input from a variety of sources, such as condensate overflow sensors and smoke

Note:

The Tracer AH541 interprets a binary input signal of 0 Vdc as a closed contact and an input signal of 24 Vdc as an open contact.

Table 12. Binary inputs

Binary input

Description Configuration Contact closed Contact open

IN7 Low temp detect 1 Normally closed Normal Latching diagnostic

IN7 DX coil defrost Normally closed Compressor(s) enabled Compressor(s) disabled

IN8 Run/stop 1 Normally open Latching diagnostic Normal

IN9 Occupancy Normally open Unoccupied Occupied

IN10 Supply fan status 1, 2 Normally open Fan on Fan off

IN11 Filter status Normally open Dirty Clean

IN12 Exhaust fan status 2 Normally closed Fan off Fan on

IN12 DX coil defrost Normally closed Compressor(s) enabled Compressor(s) disabled1 When these diagnostics occur, the controller disables all normal unit operation of fans, valves, dampers, DX, and electric heat.2 If the fan is commanded on but the status shows that it is off, the controller generates a diagnostic.

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42 CNT-SVN02B-EN

detectors. When the Tracer AH541 receives a signal to stop operation, it generates a Unit Shutdown diagnostic and stops unit operation. Using the Rover service tool, this input can also be configured as latching or non-latching. A latching diagnostic requires a manual reset to clear the diagnostic and restart the unit.

The occupancy input is used to determine whether the controller is in occupied or unoccupied mode. For more detailed information on the occu-pancy input, refer to the Tracer AH540 user guide, CNT-SVX05B-EN.

Use the Rover service tool to configure binary input IN9 as a generic input when it is not used for occupancy. A generic binary input can be monitored only from a Tracer Summit system. The binary input does not affect unit operation when configured to be generic.

The supply fan status input indicates the presence of air flow through the supply fan of the air-handler. The exhaust fan status input indicates the presence of air flow through an exhaust fan of the air-handler. Use an air flow switch (Trane part number 4190 6006) with an air flow pickup (4190 2006) for these inputs. You can also use a current sensing switch (Trane part number X13310270-01).

The filter status switch input indicates a dirty air filter. Use an air flow switch with an air flow pickup for this input.

The exhaust fan status input (IN 12) or low temp detect input (IN 7) can alternately be configured as DX coil defrost, using the Rover service tool, for DX cooling applications. Use a binary frost-stat device to indicate a frost condition on the DX cooling coil. Use frost-stat switch (Trane part number X39640722-01) for this input. For more information on DX coil defrost control, refer to the Tracer AH540 user guide, CNT-SVX05B-EN.

Wiring binary inputs

To wire a binary input:

1. Connect the common wire to a common terminal as shown in Figure 20 on page 43.

2. Connect the shield wire to a common terminal at the termination board and tape it back at the input device.

3. Connect the signal wire to the appropriate input terminal (see Figure 13 on page 24).

4. Use the Rover service tool to configure the binary input.

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Binary inputs

CNT-SVN02B-EN 43

Figure 20. Wiring a binary input

< 1000 ft(300 m)

Binary switch

Signal

Common

Shield

Tape back shield

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44 CNT-SVN02B-EN

Checking binary inputs




To check binary inputs for proper operation:

1. Make sure that the sensor is connected and powered on.

2. Set a digital multi-meter to measure Vac, then measure the voltage across the input connections at the signal and common screw terminals.

The measured voltage should be less than 0.1 Vac. If the voltage is greater than this, the input readings may change erratically.


The measured voltage should be less than 0.1 Vdc. If the voltage is greater than this, the input readings may be offset.

CAUTION




4. Set the multi-meter to measure resistance. If you completed steps 2 and 3 successfully, measure the resistance across the input.

The resistance should be less than 200 Ω when the binary input is closed and greater than 1 kΩ when it is open.


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CNT-SVN02B-EN 45

Chapter 7

Installing the circuit board

The top plastic frame, which holds the main circuit board, is not installed in the Tracer AH541 enclosure when it ships. The board can be kept in the office while the enclosure is mounted and wired. After wiring has been completed, connect the circuit board to the termination board.

To install the circuit board:


2. Verify that the 24 Vac power cable is not connected to the termination board (see Figure 23 on page 47).

3. Hold the top frame at a 90° angle to the bottom frame as shown in Figure 21.

Figure 21. Connecting the cables

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Chapter 7 Installing the circuit board

46 CNT-SVN02B-EN

4. Connect the 60-pin cable to the 60-pin slot then connect the 20-pin cable to the 20-pin slot (see Figure 21 on page 45).

The connector is keyed to the slots. If you have difficulty connecting them, make sure that the key lines up with the slot.

5. Align the snaps on the top frame with the mounting locks on the bot-tom frame, as shown in Figure 22, then push the two frames together. You will hear a click when the frames connect.

Figure 22. Connecting the frames

6. Wire the 4–20 mA analog inputs. See “Wiring 4–20 mA analog inputs” on page 39 for details.

7. For controllers with an operator display, connect the operator-display cable to the circuit board (see Figure 23 on page 47).

8. Connect the 24 Vac power connection to the termination board (see Figure 23 on page 47). The green status LED should light up.

9. Check status LEDs according to Chapter 12, “Verifying operation and communication.”

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Installing the circuit board

CNT-SVN02B-EN 47

Figure 23. Cable termination and Status LED locations

BO5

BO4

BO3

BO2

BO1

BO6

24VAC

AO4

AO3

AO6

AO5

AO2

IN3

IN2

IN1

AO1

IN6

IN7

IN5

IN11

IN12

IN10

IN9

IN8

IN4

BO

1B

O3

BO

5B

O2

BO

4B

O6

SE

RV

ICE

CO

MM

FA

NE

XFA

NT

ES

TS

TA

TU

S

Operator-display connector

24 Vac powerconnector

Supply fan LED (green)Exhaust fan LED (green)

Service Pin buttonService LED (red)

Comm LED (yellow)

Status LED (green)Test button

DX 1 or Electric 4 LED (green)DX 2 or Electric 3 LED (green)DX 3 or Electric 2 LED (green)DX 4 or Electric 1 LED (green)

®

Chapter 7 Installing the circuit board

48 CNT-SVN02B-EN

®

CNT-SVN02B-EN 49

Chapter 8

Installing the door

This chapter shows how to install and remove the enclosure door.

Installing the door

To install the enclosure door:

1. Unpack the door and check for missing or damaged parts.

Check to make sure that the magnetic latches and touch screen (if ordered) are installed. Check for any cracks in the plastic.

2. Hold the door at a 90° angle from the enclosure as shown in Figure 24.

Figure 24. Aligning the enclosure door

Operator-display connectors

®

Chapter 8 Installing the door

50 CNT-SVN02B-EN

3. Align the hinge pegs on the door with the hinge holes on the enclosure.

4. Gently lower the door until it rests securely in the hinge holes.

5. Verify that the door swings freely on the hinges and that the magnetic latches hold the door securely when it is closed.

6. For doors with an operator display, connect the operator-display cable to the operator-display connectors (see Figure 24 on page 49).

Removing the doorRemove the door to simplify wiring or when upgrading the controller with a door-mounted operator display.

To remove the enclosure door:

1. Open the door to a 90° angle from the enclosure.

2. For doors with an operator display, disconnect the operator-display cable from operator display.

3. Lift the door to pull the hinges from the hinge holes.

®

CNT-SVN02B-EN 51

Chapter 9

Installing the stand-alone

operator display

With the attached cable, the stand-alone operator display can be mounted up to 10 ft (3 m) from the Tracer AH541 controller. You can extend this distance up to 150 ft (46 m) using using four-conductor wire and the included pig-tail connectors. Alternately, use three twisted-pair wires.

Trane recommends the following four-conductor wires:

• Plenum 18 AWG, Trane part number 400-2059• Plenum 22 AWG, Trane part number 400-2020• Non-plenum, Trane part number 400-1005

CAUTION


To clean the operator display, use a cloth dampened with commercial

liquid glass cleaner. Spraying water or cleansers directly on the screen

may result in equipment damage.

To install the stand-alone operator display:

1. Unsnap the gray plastic backing from the operator display.

2. Carefully disconnect the operator-display cable from the connector inside the operator display.

3. Use the plastic backing as a template to mark the position of the four mounting holes on the mounting surface (see Figure 25 on page 52).

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Chapter 9 Installing the stand-alone operator display

52 CNT-SVN02B-EN

Figure 25. Operator-display mounting holes

4. Set the plastic backing aside and drill holes for #8 (4 mm) screws or #8 wall anchors.

5. Secure the plastic backing to the wall with #8 (4 mm) mounting screws (not supplied).

6. Connect the operator-display cable to the operator display, then snap the operator display to the plastic backing.

The operator-display cable is keyed to the connector. If you have diffi-culty connecting it, make sure the key is lined up with the slot.

7. Run the operator-display cable to the Tracer AH541, affixing it to the wall with wiring staples or wire mold. Do not run operator-display cable in the same wire bundle with high-voltage power wires. Runing input/output wires with 24 Vac power wires is acceptable.

8. Feed the cable into the Tracer AH541 enclosure.

9. Attach the operator-display cable to the operator-display connector on the circuit board (see Figure 26).

The operator display receives power from the Tracer AH541 and turns on automatically when it is connected to the controller.

Mounting hole (four locations)

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Installing the stand-alone operator display

CNT-SVN02B-EN 53

Figure 26. Operator-display connector on the Tracer AH541

BO5

BO4

BO3

BO2

BO1

BO6

24VAC

AO4

AO3

AO6

AO5

AO2

IN3

IN2

IN1

AO1

IN6

IN7

IN5

IN11

IN12

IN10

IN9

IN8

IN4

BO

1B

O3

BO

5B

O2

BO

4B

O6

SE

RV

ICE

CO

MM

FA

NE

XFA

NT

ES

TS

TA

TU

S

Operator-display connector

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Chapter 9 Installing the stand-alone operator display

54 CNT-SVN02B-EN

®

CNT-SVN02B-EN 55

Chapter 10

Connecting the portable

operator display

The portable operator display is designed for temporary connections to Tracer AH541 controllers.

CAUTION





IMPORTANTThe portable operator display is not used for time clock scheduling. To

provide scheduling, you must use a permanently-connected door-

mounted operator display, stand-alone operator display, or Tracer Sum-

mit system.

To connect the portable operator display:

1. Open the Tracer AH541 enclosure door.

2. Attach the operator-display cable to the operator-display connector on the circuit board (see Figure 26 on page 53).

The operator display receives power from the Tracer AH541 and turns on automatically when it is connected to the controller.

®

Chapter 10 Connecting the portable operator display

56 CNT-SVN02B-EN

®

CNT-SVN02B-EN 57

Chapter 11

Setting up the

operator display

This chapter shows how to set the time and date, calibrate the operator-display touch screen, and adjust the brightness and contrast.

CAUTION





Setting up time and date

To change the time for the operator display:

1. On the home screen, press the Setup button. The Setup menu appears.

2. Press the down arrow button to go to Setup menu 2 of 2.

3. Press the Change Time button to view the next screen.

4. Using the buttons, type the time using the format hh:mm, where hh is the hour and mm is the minute. Press either the AM or PM button, as appropriate.

5. To correct an error, press clear and start again. To accept the changes, press the OK button.

To change the date for the operator display:


2. Press the down arrow button to go to Setup menu 2 of 2.

3. Press the Change Date button to view the next screen.

4. Press the forward and back arrows to move the cursor from day to month to year. Use the buttons to type the appropriate date.

5. To correct an error, press the reset button. To accept the changes, press the OK button.

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Chapter 11 Setting up the operator display

58 CNT-SVN02B-EN

Calibrating the operator display

To calibrate the operator display:


2. Press the page down button to view the next screen.

3. Press the Calibrate Touch Screen button. A calibration screen appears.

CAUTION


Do not allow the operator display to come in contact with sharp

objects.

4. Touch the target using a small, pliable, blunt object, such as a pencil eraser. Hold until the beeping stops. A second calibration screen appears.

5. Again, touch the target with the object. Hold until the beeping stops. The Setup menu appears.

6. Press the Home button. The home screen appears.

®

Adjusting brightness and contrast

CNT-SVN02B-EN 59

Adjusting brightness and contrast

To adjust the brightness and contrast of the operator display:


2. Press the page down button to view the next screen.

3. Press the Adjust Brightness and Contrast button. The Brightness and Contrast screen appears.

4. To increase the brightness, press the buttons along the top row, in sequence, from left to right. To decrease the brightness, press the buttons from right to left.

5. To increase the contrast, press the buttons along the bottom row, in sequence, from left to right. To decrease the contrast, press the buttons from right to left.

6. Press the Home button. The home screen appears.

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Chapter 11 Setting up the operator display

60 CNT-SVN02B-EN

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CNT-SVN02B-EN 61

Chapter 12

Verifying operation and

communication

This chapter describes:

• Test button• Service Pin button• Light-emitting diodes (LEDs)• Diagnostic conditions• How to check the earth ground

Test buttonThe Test button is located on the main circuit board as shown in Figure 27. You can use it to perform the manual output test, which veri-fies that the controller is operating properly. The manual output test is described in the next section.

Figure 27. Service Pin button and LED locations

BO5

BO4

BO3

BO2

BO1

BO6

24VAC

AO4

AO3

AO6

AO5

AO2

IN3

IN2

IN1

AO1

IN6

IN7

IN5

IN11

IN12

IN10

IN9

IN8

IN4

BO

1B

O3

BO

5B

O2

BO

4B

O6

SE

RV

ICE

CO

MM

FA

NE

XFA

NT

ES

TS

TA

TU

S

Supply fan LED (green)Exhaust fan LED (green)

Service Pin buttonService LED (red)

Comm LED (yellow)

Status LED (green)Test button

DX 1 or Electric 4 LED (green)DX 2 or Electric 3 LED (green)DX 3 or Electric 2 LED (green)DX 4 or Electric 1 LED (green)

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Chapter 12 Verifying operation and communication

62 CNT-SVN02B-EN

Performing a manual output testThe manual output test sequentially controls all outputs to verify their wiring and operation. Normal operation of the controller is suspended while the manual output test is being performed.

You can use the manual output test to clear the controller of diagnostics. If any diagnostics are present when a manual test is initiated, the Status LED blinks twice. During the second step of the test, the controller attempts to clear the diagnostics. If the controller cannot clear a diagnos-tic, the controller exits the manual output test.

You can also use the manual output test for air and water balancing. Step four of the test provides cooling capacity. Step five provides heating capacity. Step four also opens the outdoor air damper to the minimum occupied position and controls the duct static-pressure to the duct static-pressure setpoint.

You can perform the manual output test in three ways:

• Press the Test button to proceed through the test sequence• Use the Rover service tool• Use the operator display

To perform a manual output test using the Test button:

1. Press and hold the Test button for 3 to 4 seconds, then release the button to start the test mode. The green Status LED light turns off when the Test button is pressed, and then it blinks (as described in Table 16 on page 65) when the button is released to indicate the con-troller is in manual test mode.

2. Press the Test button (no more than once per second) to advance through the test sequence. Table 13 shows the resulting activities of the outputs.

3. Finish the test by advancing through the complete test sequence. The test will end automatically if the unit remains in a single step for ten hours.

®

Performing a manual output test

CNT-SVN02B-EN 63

Table 13. Manual output test sequence

Step1

(number of times Test button is pressed in sequence)

Supply fanCool

output(s)Heat

output(s)

Face and bypass damper

Outdoor air damper

Exhaust fan

Step 1 2 Off, 0% Closed Closed Bypass Closed Off

Step 2 3 On, 0% Closed Closed Face Closed Off

Step 3 On, DSP 4 Closed Closed Face Closed Off

Step 4 On, DSP Open or On 7

Closed Face Occupied minimum position

Off

Step 5 On, DSP Closed Open or On 8

Face Occupied minimum position

Off

Step 6 On, DSP Closed Closed Bypass Open On 5

Step 7 Return to normal operation 6

1 The following diagnostics cause the Tracer AH541 to exit the manual output test:• Duct Static-pressure High Limit• Low Supply Fan Air Flow• Low Temp Detect• Unit Shutdown

2 When the manual output test starts, all outputs are turned off or closed. The status LED blinks once if there are no diagnostics and blinks twice if any diagnostics are present.

3 At the beginning of step 2, the controller attempts to clear any existing diagnostics. If the controller is unsuccessful clearing a diagnostic, the controller exits the manual output test.

4 If the controller is configured for variable-air-volume (VAV) control, the controller tests duct static-pressure (DSP) control dur-ing steps 3 through 6.

5 If an exhaust-fan status diagnostic occurs, the controller turns off the exhaust fan during step 6.6 The controller exits the test by initiating a reset and returning the controller to normal operation.7 If the Tracer AH541 cooling type is hydronic or 2-pipe changeover, the valve will open 100% in step 4. If the cooling type is DX

the first stage of cooling will be energized in step 4, and each additional DX output will energize sequentially with each Test button press (maximum of 4-stages).

8 If the Tracer AH541 heating type is hydronic or steam, the valve will open 100% in step 5. If the heat type is staged electric or analog electric the first stage of heating will be energized in step 5, and each additional electric heat output will energize sequentially with each Test button press. Staged electric can have a maximum of 4-stages. Analog electric can have a maxi-mum of 6-stages.

®


64 CNT-SVN02B-EN

Service Pin buttonThe Service Pin button is located on the main circuit board as shown in Figure 27 on page 61. You can use the Service Pin button to:

• Identify a device• Add a device to the active group in Rover• Verify communication with Rover• Make the green Status LED “wink” to verify that the controller is

communicating on the link

Refer to the Rover Operation and Programming guide, EMTX-SVX01E-EN, for information on how to use the Service Pin button.

Interpreting LEDsThe information in this section will help you interpret LED activity. The location of each LED is shown in Figure 27 on page 61.

Binary output LEDs

The FAN (BO1) LED indicates the status of the first binary output, which controls the supply fan. The EX FAN (BO2) LED indicates the status of the second binary output, which controls the exhaust fan. Binary outputs BO3, BO4, BO5, BO6 indicate the status of DX cooling and electric heat stages. Table 14 describes the LED activity for these binary outputs.

Note:

Each binary output LED reflects the status of the output relay on the circuit board. It may or may not reflect the status of the equipment the binary output is controlling. Field wiring determines whether or not the state of the binary output LED also applies to status of the end device. Table 14 describes the LED states.

Table 14. Binary output LEDs

LED activity Explanation

LED is on continuously The relay output is energized.

LED is off continuously The relay output is de-energized or there is no power to the board.

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Interpreting LEDs

CNT-SVN02B-EN 65

Service LED

The red Service LED indicates whether the controller is operating nor-mally. Table 15 describes Service LED activity.

Status LED

The green Status LED indicates whether the controller is receiving power and if the controller is in manual test mode. Table 16 describes Status LED activity.

Table 15. Red Service LED


LED is off continuously when 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 blinks 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 to normal operation using the Rover service tool. Refer to EMTX-SVX01E-EN for more information on the Rover service tool.

Table 16. Green Status LED


LED is on continuously Power is on (normal operation).

LED blinks once The controller is in manual output test mode. No diagnostics are present.

LED blinks twice The controller is in manual output test mode. One or more diagnostic is present.

LED blinks (¼ second on, ¼ second off for 10 seconds)

The auto-wink option is activated, and the controller is communicating. 1

LED blinks rapidly Flash download is being received.

LED is off continuously Either the power is off or the controller has malfunctioned.

1 By sending a request from the Rover service tool, you can request the controller’s green LED to blink (“wink”), a notification that the controller received the signal and is communicating.

®


66 CNT-SVN02B-EN

Comm LED

The yellow Comm LED indicates the communication status of the control-ler. Table 17 describes Comm LED activity.

Table 17. Yellow Comm LED


LED is off continuously The controller is not detecting any communica-tion (normal for stand-alone applications).

LED blinks The controller detects communication (normal for communicating applications, including data sharing).

LED is on continuously An abnormal condition that may occur during discovery. The LED may flash fast enough to look as if it is on continuously. If this LED activity occurs at any other time, the site may have excessive radio frequency interference (RFI).

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Interpreting diagnostics

CNT-SVN02B-EN 67

Interpreting diagnosticsThe Tracer AH541 controller generates three types of diagnostics:

• Critical—The controller shuts down the unit to prevent possible damage. The controller cannot operate until the diagnostic condition is corrected.

• Service required—The controller disables certain sequences of opera-tion while attempting to maintain unit operation. For example, if the mixed-air temperature sensor fails or is not wired, the controller dis-ables economizer operation.

• Informational—The controller operates normally.

Two or more diagnostics can be present at the same time. Diagnostics are reported in the order in which they occur, but each diagnostic has a differ-ent priority. For example, if a freezestat condition occurs, the controller communicates a Low Temp Detect diagnostic message at priority one, shuts down the air-handler, and opens all valves. If a stop input condition then occurs, the controller communicates a Unit Shutdown diagnostic message at priority two. However, because the Low Temp Detect diagnos-tic has a higher priority, the controller does not close the valves.

Tracer AH541 diagnostics have the following priorities, with 1 being the highest priority and 22 being the lowest priority:

1. Emergency Override

2. Manual Output Test

3. Low Temp Detect

4. Unit Shutdown

5. Low Supply Fan Air Flow

6. Low Exhaust Fan Air Flow

7. Space Temperature Failure

8. Duct Static Press Failure

9. Duct Static Press High Limit

10. Discharge Air Temp Failure

11. Local Space Setpoint Failure

12. Local Fan Switch Failure

13. Outdoor Air Temp Failure

14. Mixed Air Temp Failure

15. Humidity Input Failure

16. Entering Water Temp Failure

17. CO2 Sensor Failure

18. Evap Refrigerant Temp Failure

19. Generic Temperature Failure

20. Dirty Filter

21. Maintenance Required

22. Invalid Unit Configuration

®


68 CNT-SVN02B-EN

Table 18 describes Tracer AH541 diagnostics.

Table 18. Tracer AH541 diagnostics

Diagnostic Configuration Outputs

Emergency Override(informational)

CV space temp controlCV discharge-air controlVAV control

Refer to the Tracer AH540 user guide, CNT-SVX05B-EN.

Manual Output Test(informational)


See “Performing a manual output test” on page 62.

Low Temp Detect 1, 2

(critical or service required)CV space temp controlCV discharge-air controlVAV control

Supply fan: OffValves (cooling): OpenValves (heating): Open/closedDX cooling/Electric heat: DisabledElectric heat: DisabledOutdoor air damper: ClosedFace and bypass damper: FaceExhaust fan: Off

Duct Static Press High Limit 2

(critical or service required)VAV control

Supply fan: OffValves: ClosedDX cooling /Electric heat: DisabledOutdoor air damper: ClosedFace and bypass damper: BypassExhaust fan: Off

Duct Static Press Failure(critical)

Unit Shutdown 2

(critical or service required)


Low Supply Fan Air Flow 2


Discharge Air Temp Failure 2, 3


Invalid Unit Configuration 2

(service required)

Space Temperature Failure 2, 3

(critical or service required)CV space temp control

Low Exhaust Fan Air Flow(service required)


Supply fan: Normal operationValves: Normal operationDX cooling /Electric heat: Normal operationOutdoor air damper: Normal operationFace and bypass damper: Normal operationExhaust fan: Off

Outdoor Air Temp Failure 3

(service required) CV space temp controlCV discharge-air controlVAV control

Supply fan: Normal operationValves: Normal operationDX cooling /Electric heat: Normal operationOutdoor air damper: Minimum position5 Face and bypass damper: Normal operationExhaust fan: Normal operation

Mixed Air Temp Failure(service required)

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Interpreting diagnostics

CNT-SVN02B-EN 69

Space Temperature Failure(service required) CV discharge-air control

VAV control

Supply fan: Normal operationValves: Normal operationDX cooling/Electric heat: Normal operationOutdoor air damper: Normal operationFace and bypass damper: Normal operationExhaust fan: Normal operation

Humidity Input Failure(service required)

Duct Static Press Failure(informational)

CV discharge-air control

Humidity Input Failure 2

(critical or service required)CV space temp control

Entering Water Temp Failure 2, 6


Local Space Setpoint Failure(service required)


Dirty Filter(informational)

Maintenance Required(informational)

Local Fan Switch Failure(informational)

CO2 Sensor Failure(informational)

Generic Temperature Failure(informational)

Evaporator Refrigerant Temp Failure(informational)

Normal(informational)1 If the freezestat device sending the Low Temperature Detect message requires a manual reset, first reset the freezestat

device and then reset the controller.2 This diagnostic can be configured as a service required alarm or a critical alarm.3 When a local temperature, setpoint, or pressure sensor has failed after being valid, the controller generates a diagnostic

to indicate the sensor loss condition. Because this is a non-latching diagnostic, the controller automatically clears the diagnostic once a valid sensor value is present.

4 A Space Temperature Failure diagnostic disables morning and daytime warm-up sequence of operation when the con-troller is configured for constant volume discharge-air control or variable-air-volume control.

5 If the outdoor air temperature sensor or the mixed-air sensor fails or is not present, economizer operation is disabled and the outdoor air damper is opened to its minimum position.

6 If the entering water temperature sensor fails, Tracer AH541 operation will default to heating mode.

Table 18. Tracer AH541 diagnostics (Continued)

Diagnostic Configuration Outputs

®


70 CNT-SVN02B-EN

Checking the earth groundA proper earth ground is especially important in areas of high EMI or RFI, but you should always check the quality of the ground.

To check the quality of the earth ground:

WARNING

Live Electrical Voltage!

During this procedure, it is necessary to work with live electrical com-

ponents. Have a qualified licensed electrician or other individual who

has been properly trained in handling live electrical components per-

form these tasks. Failure to follow all electrical safety precautions when

exposed to live electrical components could result in death or serious

injury.


2. Inside of the enclosure at the top-right corner, remove the high-volt-age area cover plate.

3. Measure the ac voltage between the earth ground and the neutral ter-minal, as shown in Figure 28.

Ideally, the voltage should be 0 Vac. Find a different ground if the voltage exceeds 4 Vac. A higher voltage may result in:

• Danger to people touching the enclosure• Erratic communications, because the Comm5 shield, typically

attached to the earth ground, becomes ineffective as a noise drain• Erratic equipment operation, because noise may affect voltage

levels at the inputs—the controller interprets input noise as changes in temperature, humidity, pressure, and so on

®

Checking the earth ground

CNT-SVN02B-EN 71

CAUTION

Avoid Personal Injury!

If the earth ground has a voltage of more than 4 Vac, use a different

ground. Failure to do so may result in personal injury.

Figure 28. Checking the earth ground

4. Replace the cover plate.

WARNING

Hazardous Voltage!

The cover plate must be in place when the controller is operating. Fail-

ure to replace the cover plate could result in death or serious injury.

®


72 CNT-SVN02B-EN

CNT-SVN02B-EN 73

®

Index

Numerics

0–10 Vdc outputscheck-out procedure, 29wiring, 28

24 Vac powerand input/output wiring, 21for frame-mounted Tracer AH541, 5

A

ac power, see high-voltage poweradditional components, 2adjusting brightness and contrast for

the operator display, 59agency listing/compliance, 2air flow pickup, 42air flow switch, 42analog inputs

4–20 mA, 39, 46wiring, 33wiring guidelines, 21wiring zone sensors, 31

analog outputscheck-out procedures, 29overview, 19wiring, 28wiring guidelines, 21

B

bill of materials, 4binary inputs

check-out procedure, 44wiring, 41wiring guidelines, 21See also universal inputs

binary outputscheck-out procedure, 27inrush current, 26LEDs, 64overview, 19powered outputs, 26wiring, 25wiring guidelines, 21

board, circuit, see circuit boardbrackets for wire ties, 22

C

calibrating the operator display, 57check-out procedures, 18

0–10 Vdc outputs, 29analog outputs, 29binary inputs, 44binary outputs, 27pressure sensors, 18thermistor inputs, 36zone sensors, 32

circuit boardinstalling, 45–47LED locations, 61

circuit requirements, 11cleaning the operator display, 51clearances

for enclosure, 8for frame-mounted Tracer AH541, 5

CO2 Sensor Failure diagnostic, 69CO2 sensor input, 33Comm5

grounding to reduce EMI/RFI, 70jack location, 24LED, 66LED location, 47, 61screw-terminal location diagram, 24

compliance information, 2components, additional, 2conductor requirements, 12conduit sizes, 9, 12connector

24 Vac power, 47duct static-pressure, 16, 24operator-display cable, 47, 49stand-alone operator display, 51

current sensing switch, 42current, inrush, 26

D

DAC profile, 1diagnostics, 67–69, ??–69dimensions, 1, 9Dirty Filter diagnostic, 69Discharge Air Controller (DAC) profile,

1Discharge Air Temp Failure diagnostic,

68

Index

74 CNT-SVN02B-EN

®

distance, maximum for input/output wires, 21

door, installing, 49–50duct, 16duct static connector, 18Duct Static Press Failure diagnostic,

68, 69Duct Static Press High Limit

diagnostic, 68duct static-pressure input, 16

E

earth ground, 70electronics board, see circuit boardEmergency Override diagnostic, 68enclosure

clearances, 8dimensions, 9installing the door, 49–50knockout for high-voltage power,

12knockout sizes and locations, 9list of parts, 4mounting, 10NEMA specifications, 5, 7removing the door, 50routing wires, 21

Entering Water Temp Failure diagnostic, 69

Evaporator Refrigerant Temp diagnostic, 69

F

filter status switch, 42frame-mounted Tracer AH541

24 Vac power, 5clearances, 5enclosure requirements, 5installing, 5–6list of parts, 4model number, 11

freezestat, 41frost-stat switch, 42

G

Generic Temperature Failure diagnostic, 69

grounding the controller, 70guidelines

for high-voltage power wiring, 11for input/output wiring, 21for routing wires, 21for selecting a mounting location,

7

H

high-voltage powerand input/output wiring, 21circuit requirements, 11knockout location and size, 12screw-terminal locations, 13wiring, 12–14wiring diagram, 13

Humidity Input Failure diagnostic, 69

humidity specification, 1, 7

I

IN13, 39input tubes for pressure sensors, 16input/output wiring guidelines, 21inputs, see analog inputs, binary

inputsinrush current, 26installation category, 1installing

circuit board, 45–47enclosure, 10enclosure door, 49–50frame-mounted Tracer AH541, 5–

6high-voltage power wire, 12–14portable operator display, 55pressure sensors, 15–16stand-alone operator display, 51–

52termination board in separately

purchased enclosure, 6Invalid Unit Configuration

diagnostic, 68

K

knockoutsfor high-voltage power, 12sizes and dimensions, 9

L

LEDsbinary outputs, 64Comm (yellow), 66locations, 61Service (red), 65Status (green), 65

length, maximum for input/output wires, 21

list of parts, 4Local Fan Switch Failure diagnostic,

69

Local Space Setpoint Failure diagnostic, 69

location for mounting, 7LonMark

Discharge Air Controller (DAC) profile, 1

Space Comfort Controller (SCC) profile, 1

Low Exhaust Fan Air Flow diagnostic, 68

Low Supply Fan Air Flow diagnostic, 68

Low Temp Detect diagnostic, 68low temperature detection, 41

M

Maintenance Required diagnostic, 69

manual output test, 61–63Manual Output Test diagnostic, 68minimum clearances

for enclosure, 8for frame-mounted Tracer AH541,

5Mixed Air Temp Failure diagnostic,

68model numbers, 11mounting

enclosure, 10frame-mounted Tracer AH541, 6location requirements, 7pressure sensors, 15–16

multi-meter, expected readings, 18

N

National Electrical Code, 5, 12, 21National Electrical Manufacturers

Association (NEMA) specifications, 5, 7

O

operating environment, 1, 7operator display

adjusting brightness and contrast, 59

calibrating, 57cleaning, 51connector locations, 47, 49installing the portable model, 55installing the stand-alone model,

51–52Outdoor Air Temp Failure

diagnostic, 68

Index

CNT-SVN02B-EN 75

®

outputs, see analog outputs, binary outputs

P

parts, list of, 4pilot relays, 26pollution specification, 1power

high-voltage requirements, 1, 7, 11

transformer, 2, 12See also 24 Vac power, 24 Vdc

power, high-voltage powerpowered outputs, 26pressure sensors

connector location, 16, 24input tubes, 16installing, 15–16when to wire, 21

R

removing the door, 50required tools, 3requirements

conductors, 12enclosure for frame-mounted

Tracer AH541, 5high-voltage power, 1, 7, 11input/output wiring, 21mounting, 7National Electrical Code, 5, 12, 21operating environment, 1, 7storage, 1weight, 1, 7

resistance characteristics of sensors, 37

resistance temperature detectorswiring, 33

routing wires, 21Rover service tool, 64

S

SCC profile, 1scheduling, 55screw terminals

Comm5, 24common, 26high-voltage power, 13location diagram, 24

sensorsinstalling pressure sensors, 15–

16resistance characteristics, 37wiring zone sensors, 31

zone sensor options, 30zone sensors, 30–32

Service LED, 65Service Pin button, 64setpoint thumbwheel, 30Space Comfort Controller (SCC)

profile, 1space relative humidity, 33Space Temperature Failure

diagnostic, 68, 69specifications

agency listing/compliance, 2dimensions, 1enclosure for frame-mounted

Tracer AH541, 5high-voltage power

requirements, 1, 7humidity, 1, 7input/output wiring, 21installation category, 1NEMA, 5, 7operating environment, 1, 7pollution, 1power transformer, 2storage, 1temperature, 7weight, 1, 7

status indicators for operation and communication, 61–65

Status LED, 65storage specifications, 1

T

temperatureentering water, 33evaporator refrigerant, 33generic, 33

temperature specificationsoperating environment, 1, 7storage, 1

terminals, see screw terminalstermination board

connecting to circuit board, 45installing in separately purchased

enclosure, 6Test button, 61–63thermistor inputs

check-out procedure, 36wiring, 33

time clock, 55tools, required, 3transducer, see pressure sensorstransformer, power, 2, 12troubleshooting

diagnostics, 67–69, ??–69manual output test, 61–63Service Pin button, 64Test button, 61–63

tubes for pressure sensors, 16

U

Unit Shutdown diagnostic, 42, 68universal analog input,

configurations, 33

V

Vac power, see 24 Vac powervariable resistance inputs, wiring,

33Vdc power, see 24 Vdc powervoltage

expected multi-meter readings, 18

utilization range, 12

W

weight specifications, 1, 7wire ties, locations for, 22wiring

analog inputs, 33analog outputs, 28binary inputs, 41binary outputs, 25guidelines for input/output

wiring, 21high-voltage power, 12–14length of input/output wires, 21routing in enclosure, 21variable resistance inputs, 33wire-tie bracket locations, 22zone sensors, 31

wiring diagramsanalog outputs, 28binary input, 43binary outputs, 26high-voltage power, 13screw-terminal location diagram,

24variable resistance analog inputs,

35zone sensor, 31

Z

zone sensors, 30–32check-out procedure, 32wiring, 31

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. Only qualified technicians should perform the installa-tion and servicing of equipment referred to in this publication.

Literature Order Number CNT-SVN02B-EN

File Number SV-ES-CNT-SVN02B-EN-0204

Supersedes SV-ES-CNT-SVN02A-EN-December 2001

Stocking Location InlandTraneA business of American Standard Companieswww.trane.com

For more information, contact your local Trane office or e-mail us at [email protected]

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Hardware Installation Tracer AH541 Version 2 Air-Handler ... · Tracer™ AH541 Version 2 Air-Handler Controller ... • Minimum clearances as shown in ... enclosure is mounted in