Engineering Bulletin. IntelliPak RTM (Rooftop Module, 1U48) Subject: Generic Building Automation System (GBAS, UCM Module, 1U51)

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1 Engineering Bulletin IntelliPak RTM (Rooftop Module, 1U48) Subject: Generic Building Automation System (GBAS, UCM Module, 1U51) Issued By: Clarksville Marketing and Sales Support Order No. UN-PRB001-EN Date: AUGUST 2002 Generic Building Automation System (GBAS, UCM Module, 1U51) The purpose of this engineering bulletin is to provide the necessary information required for field connection, assignment and set-up for the four analog inputs, one binary input, and five binary outputs of the optional Generic Building Automation Systems Module, 1 U51. The GBAS is used as an interface between the IntelliPak UCM controls and non-trane building automation systems. This document also includes references to several other inputs and outputs that may be available for control by others.

3 With the GBAS module installed on the unit, up to four of the Set point Control Parameters or Output Control Parameters can be assigned to each of the 4 analog inputs of the GBAS module. Any combination of the Set point Control Parameters and/or the Output Control Parameters can be assigned to the analog inputs through the onboard Human Interface. An external 0-5 VDC signal can be applied directly to the signal input terminals or the 5 VDC source at the GBAS module can be used in conjunction with a 3-wire potentiometer to provide the signal, see figure 2. Companion Documents: SAHF- PTG - 5 Programming and Troubleshooting Guide (Constant Volume Units) SAHF- PTG - 6 Programming and Troubleshooting Guide (Variable Air Volume Units) SXH_- IOM 9 IntelliPak Installation Operation Manual UCM Control System: Trane IntelliPak Commercial Rooftop Units are controlled by a microelectronic control system that consists of a network of modules and are referred to as Unit Control Modules (UCM). The unit size, type constant volume or variable air volume (CV or VAV), heating functions, peripheral devices, options, relief capabilities, etc. determine the number and type of modules that a particular rooftop unit may employ. The UCM receives analog and binary inputs, then processes this information and supplies outputs in the form of modulating voltages, contact closures, etc. to control damper actuators, fan motors, compressors, valves, electric heating coils and other electrical devices in the unit to maintain set comfort levels. Rooftop Module (RTM) (1U48) (Standard on all units) The RTM is the central processor of the system. It continuously receives information from the other unit modules, sensors, the remote control panel, and customer supplied relays. It then interprets this information and responds to cooling, heating, and ventilation requests by directing the other modules in the system to energize the proper unit components. It also directly initiates supply and relief fan operations, and economizer operation. Generic Building Automation System Module (1U51) option, used with non-trane building control systems. The Generic Building Automation System (GBAS) module allows a non-trane building control system to communicate with the rooftop unit and accepts external setpoints in the form of 0 to 5 VDC controlling cooling, heating, supply air and space pressure setpoints. There is also a binary input available for demand limiting and five binary outputs. Refer to the "Field Installed Control Wiring" section of the current Installation Operation Manual for the input wiring to the GBAS module and the various desired setpoints with the corresponding DC voltage inputs for both VAV and CV applications. The GBAS has no analog outputs. 1

4 GBAS INPUT INFORMATION Use the following information to determine which set points are eligible to be assigned to the four GBAS analog inputs; also the scaling of the inputs is indicated Notes on GBAS analog inputs: 1. Input voltages less than 0.5 VDC will be considered as 0.5 VDC. 2. Input voltages greater than 4.5 VDC will be considered to be 4.5 VDC. 3. The actual measured voltage will be displayed at the Human Interface. If the GBAS input signal is lost, the setpoint will "clamp" to the low end of the setpoint scale; no diagnostic will result from this condition. Available GBAS analog inputs. You may use up to four analog inputs for either CV or VAV applications. See SAHF-PTG-5 (Constant Volume Units) and SAHF-PTG-6 (Variable Air Volume Units) Programming and Troubleshooting Guides for instructions on mapping GBAS inputs at the IntelliPak Human Interface. Table 1 UNIT TYPE VAV CV SET POINT INPUT VOLTAGE X Occupied Zone Cooling Setpoint 0.5 to 4.5 VDC X X Unoccupied Zone Cooling Setpoint 0.5 to 4.5 VDC X X Occupied Zone Heating Setpoint 0.5 to 4.5 VDC X X Unoccupied Zone Heating Setpoint 0.5 to 4.5 VDC X SA Cooling Setpoint 0.5 to 4.5 VDC X SA Heating Setpoint: 0.5 to 4.5 Hydronic or Modulating Gas Heat VDC X X Space Static Pressure Setpoint 0.5 to 4.5 VDC X SA Static Pressure Setpoint 0.5 to 4.5 VDC X X Minimum Outside Air Flow Setpoint 0.5 to 4.5 * VDC SET POINT TABLE RANGE 50 F to 90 F 3 50 F to 90 F 3 50 F to 90 F 3 50 F to 90 F 3 40 F to 90 F 4 40 F to 180 F to 0.3 IWC to 5.0 IWC 7 0 CCFM to UMA** 8 (a-f) * Traq Sensing - Design Special Only, Ventilation Control Module (VCM) Required ** CCFM = CFM X 100, Unit Max Airflow (UMA) Based on Unit Capacity (see Unit Max Airflow Table 8) 2

5 GBAS INPUT/OUTPUT LABELING The schematic wiring diagram on units produced between October 1993 and July 1994 have GBAS binary outputs incorrectly labeled. The Installation, Operation, Maintenance (IOM) literature for the same time period is also incorrect. Table 2 is correct. Table 2 INPUTS BINARY OUTPUTS # Terminal Strip # Terminal Strip positive (+) negative (-) common normally open normally closed 1 1TB17-1 1TB TB16-2 1TB16-1 1TB TB17-3 1TB TB TB TB TB17-7 1TB TB TB TB TB17-9 1TB TB TB TB17-19 * 1TB5-1 1TB TB TB TB17-22 * This is the GBAS demand limit binary input. Note: that the numerical designations of each output relay (e.g., GBAS Output Number 1) refers to the nomenclature shown on the Human Interface display. Use the following tables to determine the voltage/setpoint relationships for the various setpoint assignments. Review Table 1 for cross reference information. IPV = Input Voltage SP = Set Point Occupied/Unoccupied Heating and Cooling Zone Temperature Setpoints and Input Voltage Table 3 GBAS Input Voltage / Set Point ( for F ) IPV SP IPV SP IPV SP IPV SP

6 Supply Air Temperature Cooling Setpoint and Input Voltage Table 4 GBAS Input Voltage / Set Point ( for F ) IPV SP IPV SP IPV SP IPV SP Supply Air Heating Temperature Setpoint and Input Voltage Table 5 GBAS Input Voltage / Set Point ( for F ) IPV SP IPV SP IPV SP IPV SP

7 Table 5 Continued Space Static Pressure Setpoint and Input Voltage Table 6 GBAS Input Voltage / Set Point ( for IWC ) IPV SP IPV SP IPV SP IPV SP Supply Pressure Setpoint and Input Voltage Setpoint Range is IWC at Human Interface Table 7 GBAS Input Voltage / Set Point ( for IWC ) IPV SP IPV SP IPV SP IPV SP

8 Maximum Outside Air Flow With Ventilation Control Module (Traq Sensing) and GBAS Module Installed Table 8 Unit Capcity (Tons) Maximum (CCFM) UNIT MAX AIRFLOW Table Unit Capcity (Tons) Maximum (CCFM) a d b e c f Table If CO2 Sensing is employed with the VCM Module (Traq Sensing)The CO2 Input to the RTM takes precedence over the GBAS Input. Use the following tables to determine the voltage/setpoint relationships for the various Minimum Outside Air Flow Setpoint assignments. Review Table 8 for cross reference information. Outside Air Flow Setpoint and Input Voltage Tables Table 8a GBAS Input Voltage / Set Point ( for CCFM ) IPV SP IPV SP IPV SP IPV SP

9 Table 8a Continued Table 8b GBAS Input Voltage / Set Point ( for CCFM ) IPV SP IPV SP IPV SP IPV SP

10 Table 8b Continued Table 8c GBAS Input Voltage / Set Point ( for CCFM ) IPV SP IPV SP IPV SP IPV SP

11 Table 8c Continued Table 8d GBAS Input Voltage / Set Point ( for CCFM ) IPV SP IPV SP IPV SP IPV SP

12 Table 8d Continued Table 8e GBAS Input Voltage / Set Point ( for CCFM ) IPV SP IPV SP IPV SP IPV SP

13 Table 8e Continued

14 Table 8e Continued Table 8f GBAS Input Voltage / Set Point ( for CCFM ) IPV SP IPV SP IPV SP IPV SP

15 Table 8f Continued

16 14 Table 8f Continued

17 Formulas for calculating input voltage or set point: IPV = Input Voltage SP = Set Point IPV IPV ( )( 0.1) ( 0.5) = SP 50 + ( )( 0.08) ( 0.5) = SP F, F, IPV 05. SP = + ( 50) SP = IPV ( 40) IPV IPV F ( )( ) ( 0.5) = SP 40 + = ( SP 003. )( 148. ) + ( 05. ), IWC, 0.5 SP = IPV ( 40) IPV 05. SP = + ( 003. ) IPV ( )( 0.8) + ( 0.5), = SP IWC SP = IPV CFM [Unit Max Airflow] (see Table 3 Above) IPV = 4.0 [ UnitMaxAirflow] ( SP) + ( 0.5), ( IPV 0.5)[ UnitMaxAirflow] SP =

18 USE OF POTENTIOMETERS WITH GBAS MODULE 1U51 As an alternative to the use of an external 0-5 VDC signal, a potentiometer may be used to provide a setpoint. There is one regulated 5 VDC output on the GBAS module which may be used with a potentiometer as a voltage divider. An example of this is shown on drawing 2. Recommended potentiometer value is from 1KΩ to 100KΩ. RTM ( Roof Top Module ), 1U48, SETPOINT ANALOG INPUTS See table 11 for terminal strip connection points. Table 9 RTM cooling or heating setpoint input used as the source for a ZONE temp setpoint ( F) RTM cooling setpoint input used as the source for SUPPLY AIR temp setpoint - cooling ( F) Resistance (Ω) N/A N/A RTM, 1U48, MODE INPUTS Table 10 Resistance applied to RTM MODE input terminals (Ω) Constant Volume Units Fan mode System mode VAV Units System mode 2320 AUTO OFF OFF 4870 AUTO COOL AUTO AUTO AUTO ON OFF ON COOL ON AUTO AUTO HEAT ON HEAT --- Mode Boundaries: The lower boundary is 1 kω.; the upper boundary is 40kΩ. Other boundaries are equal to the midpoint between the nominal mode resistance s. See table 11 for terminal strip connection points. 16

19 Table 11 RTM TERMINAL STRIP INPUTS FOR SET POINTS AND MODES COMMON ZONE COOLING ZONE HEATING SUPPLY AIR MODE VAV 1TB4-2 1TB4-3 1TB4-5 1TB4-3 1TB4-4 RTM, 1U48, TEMPERATURE SENSORS All Temperature Sensors used with IntelliPak and Voyager rooftops are thermistors with the SAME temperature-resistance characteristic curve: Keystone Carbon D97 Material. Tolerances are ±1 C. Table 12 is temperature vs. resistance, and table 15 is sensor terminal strip hook up locations. Table 12 TEMPERATURE DEGREES F TEMPERATURE ( F) RESISTANCE (kω) TEMPERATURE ( F) RESISTANCE (kω)

20 The following binary and analog connections may be used in conjunction with the GBAS module to extend the available inputs for non Trane building automation controls. These connections are available with or without the GBAS module. EMERGENCY STOP (w/ HIGH DUCT TEMP. TSTAT), AND EXTERNAL AUTO/STOP Emergency Stop and External Auto/Stop stop the unit immediately, Emergency Stop generates a manual reset diagnostic that must be reset at the unit human interface. External Auto-Stop will return the unit to the current operating mode when the input is closed, so this input is auto reset See Table 14 for terminal strip hook-up locations. UNOCCUPIED MODE The unoccupied mode is entered when the unoccupied binary input is closed. The supply fan stops and the economizer closes. On VAV units the inlet guide vanes go full open and the unoccupied relay contacts change. The fan starts on a call for heating or cooling when the unit reaches an unoccupied heating or cooling setpoint. When that setpoint is satisfied the fan stops. If MWU (Morning Warm Up) is enabled and the sensor selected to be used for MWU is below the MWU setpoint; when the unoccupied binary contacts open, the unit enters the MORNING WARM UP MODE. The fan and the heat come on with the economizer closed until the morning warm-up set point is reached. When this set point is reached the fan stops, the economizer strokes to the minimum position, and on VAV units the inlet guide vanes close and the unoccupied relay changes. When the VAV box stroke time is met the unit enters the occupied mode, the fan starts. If MWU is not required disable the function in the Setup Menu. See Table 14 for terminal strip hook-up locations. CHANGEOVER This mode only functions on units configured as VAV with HYDRONIC or Modulating Gas heat. When the changeover binary input is closed the unit will control to a discharge air heating setpoint. This setpoint is entered from the unit Human Interface or the GBAS module and can be a higher temperature than the supply air cooling setpoint. RTM, 1U48, BINARY INPUT CONNECTIONS Table 13 RTM BINARY INPUTS Description Terminal Strip Locations Emergency Stop 1TB4-15 1TB4-16 High Duct Temp. Tstat** 1TB7-7 * 1TB7-8 * External Auto/Stop 1TB4-17 * 1TB4-18 * Unoccupied ( night set back ) 1TB4-18 1TB4-19 Changeover 1TB5-21 1TB5-22 * Remove factory jumper. ** Wired in series with Emergency Stop RTM, 1U48, REMOTE ECONOMIZER MINIMUM POSITION The remote minimum position potentiometer BAYSTAT023A provides a variable resistance (0-270Ω) for adjustment of Economizer Minimum Position from 0 to 100% when connected to the Economizer Remote Minimum Position Input of the RTM. RTM must be selected as the Source for Economizer Minimum Position. On VAV units the Outside Air Compensation input must be disabled for the Remote Economizer Minimum Position input to function. Terminal strip inputs are shown in Table

21 Economizer Remote Minimum Position Input resistance chart: Table 14 Input Resistance Economizer Minimum Position 0-30 Ω 0 % Ω % (Linear) Ω 100 % > 350 Ω N/A * * Resistance s greater than 350 Ω are assumed to be an open circuit. The system will in that case use the Default Minimum Position value. RTM, 1U48 TERMINAL STRIP CONNECTIONS FOR SENSORS Table 15 SENSOR DESCRIPTION TERMINALS RTM ZONE TEMP. 1TB4-1 1TB4-2 RTM AUX. TEMP. 1TB4-11 1TB4-13 RTM ECON MIN POSITION POT 1TB5-8 1TB5-9 RTM, 1U48, ANALOG OUTPUTS The RTM has two 0-10 VDC outputs, one for the inlet guide vanes, and one for the economizer if the unit is configured with these options. These outputs will provide a signal for one or two damper actuators. There are no terminal strip locations associated with these wires. They go directly from pins on the RTM circuit board to the actuator motor. Terminal locations are in Table 16. Table 16 Inlet Guide Vane Economizer Actuator Economizer Min. Pos. RTM Terminal Location RTM Terminal Location Terminal Strip Location (+) J4-1 (-) J4-2 (+) J6-1 (-) J6-2 1TB5-8 1TB5-9 RTM, 1U48, BINARY OUTPUTS The RTM has an output for the supply fan and exhaust fan if so configured. Both of these outputs have pressure switch proving inputs. There is a 5 minute delay from the time the RTM issues a command to start the supply fan until the fan proving input must close. A fan failure diagnostic will occur after 5 minutes. This is a manual rest diagnostic, all heating, cooling and economizer functions will be locked out. If the proving input opens during fan operation, a diagnostic is generated after 40 seconds. If this proving input is jumped other nuisance diagnostics will occur. The exhaust fan proving input functions the same as the supply fan proving function. If the proving input fails to close in 40 seconds the economizer is cycled to the minimum position, and the exhaust fan is cycled off. This is a manual reset diagnostic. External control of these two fans is not recommended. 19

22 UNOCCUPIED BINARY OUTPUT RELAY This is a single pole double throw relay, rated at a maximum voltage of 24 VAC, 2 amps max. The contacts of this relay switch when the unit goes from the occupied mode to the unoccupied mode by means of the unoccupied binary input. The contacts will stay switched during these modes of operation: unoccupied, morning warm up, and daytime warm up. The contacts will return to the position shown on the unit schematic when the unit returns to the occupied mode. The intent of this binary output is to signal the VAV boxes or other terminal devices to go to a full open airflow position. The terminal connections are shown in Table 17. ALARM RELAY This is a single pole double throw relay, rated at a maximum voltage of 24 vac, 2 amps max. The contacts of this relay can be programmed from the unit Human Interface. This relay can be programmed to pick up on any one or group of diagnostics from the unit human interface. The terminal connections are shown in Table 17. Table 17 UNOCCUPIED OUTPUT RELAY ALARM OUTPUT RELAY TERMINAL # TERMINAL # COMMON NO NC COMMON NO NC 1TB TB TB TB TB TB16-17 OTHER USEFUL INFORMATION Trane recommends the heating and cooling stages are controlled by changing the unit set points. The unit safeties and anti short cycle timers are integrated into our controls. Anyone who assumes direct control of these functions should be prepared to assume compressor and heat exchanger warranty responsibility. 20

23 Figure 1 Typical GBAS Analog Input Wiring Diagram for CV & VAV Control Options 21

24 Figure 2 GBAS Module for both CV & VAV Control Options 22

26 Trane A business of American Standard Companies For more information contact your local district office or us at comfort@trane.com Literature Order Number UN-PRB001-EN File Number UN-PRB001-EN 08/02 Supersedes RT-EB-109 Stocking Location Eagle, TraneNet Trane has a policy of continuous product data and product data improvement and reserves the right to change design and specifications without notice.

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