Hardware Installation. Tracer AH541 Version 2 Air-Handler Controller CNT-SVN02B-EN

Hardware Installation Tracer AH541 Version 2 Air-Handler Controller CNT-SVN02B-EN

Hardware Installation Tracer AH541 Version 2 Air-Handler Controller CNT-SVN02B-EN February 2004

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 person 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. CNT-SVN02B-EN

NOTICE: Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully: WARNING Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. CAUTION Indicates 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. CAUTION Indicates 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: IMPORTANT Alerts 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. Note: A note may be used to make the reader aware of useful information, to clarify a point, or to describe options or alternatives. This symbol precedes a procedure that consists of only a single step. CNT-SVN02B-EN

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 CNT-SVN02B-EN v

Contents 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 vi CNT-SVN02B-EN

Contents 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 CNT-SVN02B-EN vii

Contents viii CNT-SVN02B-EN

Chapter 1 Overview This guide shows how to install the Tracer AH541 air-handler controller. Product description The Tracer AH541 air-handler controller is a low-cost, direct digital controller. 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 airhandler 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) Specifications The 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) Weight 16 ½ in. 14 ¾ in. 5 ½ in. (418 mm 373 mm 140 mm) 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 phase Other: 196 264 Vac, 1 A maximum, 1 phase CNT-SVN02B-EN 1

Chapter 1 Overview Agency listing/compliance UL and C-UL: UL 916 Energy Management CUL C22.2 No. 205-M1985 Signal Devices FCC: CFR 47, Part 15, Subpart A, Class A CE: Emissions EN55022 Class B EN61000-3-2 EN61000-3-3 Immunity EN50082-2 Industrial Additional components The 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 2 CNT-SVN02B-EN

Required tools Figure 1. Operator display models Door-mounted operator display Stand-alone operator display Portable operator display Required tools To 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 CNT-SVN02B-EN 3

Chapter 1 Overview Inspection upon receipt Make 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 framemounted Tracer AH541 are not supplied. 4 CNT-SVN02B-EN

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 requirements Before 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 electrical codes for high-voltage power wiring to the enclosure 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. Figure 2. Frame-mounted Tracer AH541 minimum clearances ½ in. (13 mm) BO1 BO2 BO3 BO4 BO5 BO6 6 in. (152 mm) for I/O wires 24VAC AO1 AO2 AO3 AO4 AO5 AO6 IN1 IN2 IN3 ½ in. (13 mm) ½ in. (13 mm) IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 3 in. (76 mm) for communications wires CNT-SVN02B-EN 5

Chapter 2 Installing the frame-mounted Tracer AH541 Installing the termination board To install the termination board in a separately purchased enclosure 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 components, follow the instructions in the following chapters. 6 CNT-SVN02B-EN

Chapter 3 Mounting the enclosure This chapter describes location requirements and shows how to mount the Tracer AH541 enclosure. 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. Selecting a mounting location Make sure that the location meets the operating environment requirements and clearance requirements described in the following sections. The Tracer AH541 controller must be installed indoors. Trane recommends 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. 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 Weight Altitude 6500 ft (2000 m) North America: 98 132 Vac, 1 A maximum, 1 phase Other: 196 264 Vac, 1 A maximum, 1 phase Mounting surface must be able to support 25 lb (12 kg) CNT-SVN02B-EN 7

Chapter 3 Mounting the enclosure Clearances Make sure that the mounting location has enough room to meet the minimum clearances shown in Figure 4. Figure 5 on page 9 shows the dimensions of the Tracer AH541 enclosure. Figure 4. Minimum clearances for enclosure 12 in. (30 cm) 24 in. (60 cm) to fully open door 12 in. (30 cm) 12 in. (30 cm) 50 in. (130 cm) recommended 36 in. (90 cm) 8 CNT-SVN02B-EN

Selecting a mounting location Figure 5. Tracer AH541 enclosure dimensions Top Left Front Right Bottom Note: Six of the twelve knockouts are dual-sized knockouts for 1-inch (25 mm) and ¾-inch (19 mm) conduit. CNT-SVN02B-EN 9

Chapter 3 Mounting the enclosure 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 Mounting hole (four locations) 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. 10 CNT-SVN02B-EN

Chapter 4 Wiring high-voltage ac power This chapter shows how to wire high-voltage ac power to the enclosure. Local power requirements The 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 number on the shipping label or on the product label inside the enclosure. Table 3. Tracer AH541 models Model Number BMTA000AA0A0 BMTA000AA0A1 BMTA000BA0A0 BMTA000BA0A1 BMTA000CA0A0 Description Enclosure, 120 Vac Enclosure, 120 Vac, with operator display Enclosure, 230 Vac, CE-compliant Enclosure, 230 Vac, with operator display, CE-compliant Frame-mounted, 24 Vac, CE-compliant Circuit requirements To 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 disconnecting 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 conroller. Failure to comply may cause the controller to malfunction due to electrical noise. CNT-SVN02B-EN 11

Chapter 4 Wiring high-voltage ac power 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. Note: The voltage utilization range for the Tracer AH541 transformer is 98 132 Vac (120 Vac nominal) or 196 264 Vac (230 Vac nominal). The panel detects whether the current is 50 or 60 cycle. Wiring high-voltage power WARNING Hazardous Voltage! Before making electrical connections, lock open the supply-power disconnect 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. IMPORTANT Make 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). 12 CNT-SVN02B-EN

Wiring high-voltage power Figure 7. Knockout for high-voltage power wires Power wire entry through knockout for ½-inch conduit 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-voltage 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 Conduit Ground wire to ground screw Line wire to L terminal Neutral wire to N terminal 7. Connect the neutral wire to the N terminal. CNT-SVN02B-EN 13

Chapter 4 Wiring high-voltage ac power 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. Failure 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. 14 CNT-SVN02B-EN

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 installation of the pressure sensor, mount and wire it before wiring the other inputs and outputs. IMPORTANT When configured for variable-air-volume control, the Tracer AH541 controller must receive a valid duct static-pressure value to operate properly. 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 constantvolume space-temperature control or constant-volume discharge-air temperature control. CNT-SVN02B-EN 15

Chapter 5 Installing the pressure sensor Installing the pressure sensor IMPORTANT Use 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 Pressure sensor mounting holes 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. 16 CNT-SVN02B-EN

Installing the pressure sensor Figure 10. Wiring the pressure sensor Duct static connector CNT-SVN02B-EN 17

Chapter 5 Installing the pressure sensor Checking the pressure sensor You can check the pressure sensor for proper operation only after supplying 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 discussed in table Table 4. Figure 11. Connecting the multi-meter to the duct static input Green Black Red Duct static connector on termination board 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. 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 For additional troubleshooting information, refer to the Tracer AH540 user guide, CNT-SVX05B-EN. 18 CNT-SVN02B-EN

Chapter 6 Wiring inputs and outputs This chapter shows how to wire and test Tracer AH541 inputs and outputs. 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 terminal 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 humidity CO 2 sensor Entering water temperature Evaporator refrigerant temp Generic temperature Current: 4 to 20mA Current: 4 to 20mA Thermistor Thermistor Thermistor 1 Resistance temperature detector (RTD), 1000 Ω at 32 F (0 C), 385 platinum curve. Table 6. Outputs 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) 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 CNT-SVN02B-EN 19

Chapter 6 Wiring inputs and outputs Table 6. Outputs (Continued) Output Function Maximum output rating AO6 Not used BO1 Supply fan start/stop 12 VA BO2 Exhaust fan start/stop 12 VA BO3 DX stage 1 or Electric 12 VA heat stage 4 BO4 DX stage 2 or Electric 12 VA heat stage 3 BO5 DX stage 3 or Electric 12 VA heat stage 2 BO6 DX stage 4 or Electric heat stage 1 12 VA Required inputs The 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. 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 Mixed-air temperature Duct static-pressure Space relative humidity Entering water temperature Economizer control Economizer control Variable-air-volume control SCC or DAC configuration 1 SCC or DAC configuration 1 DAC configuration Space Dehumidification SCC configurations 1 2-pipe changeover SCC configurations 1 1 A communicated value will allow this function to operate without a locally wired sensor. 20 CNT-SVN02B-EN

Required tools Required tools To 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 guidelines Input/output wiring must meet the following guidelines: Wiring must conform with the National Electrical Code and local electrical codes. Use only 18 22 AWG (1.02 0.643 mm 2 ), 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 highvoltage 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 routing Figure 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. CNT-SVN02B-EN 21

Chapter 6 Wiring inputs and outputs Figure 12. Wire routing Brackets for wire ties (9 locations) Pressure sensor will affect wire routing Recommended communication wire route 22 CNT-SVN02B-EN

Screw-terminal locations Screw-terminal locations Figure 13 on page 24 shows the location of the screw-terminals on the termination 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. CNT-SVN02B-EN 23

Chapter 6 Wiring inputs and outputs Figure 13. Screw-terminal locations Common terminals Signal terminals BO1 Supply fan start/stop BO2 Exhaust fan start/stop BO3 DX stage 1 or Elec. heat stage 4 BO4 DX stage 2 or Elec. heat stage 3 BO5 DX stage 3 or Elec. heat stage 2 BO6 DX stage 4 or Elec. heat stage 1 AO1 Supply fan speed AO2 Cool output AO3 Heat output AO4 Face and bypass damper AO5 Outdoor air damper IN1 Space temp IN2 Space setpoint IN3 Fan-mode switch IN4 Discharge-air temp IN5 Outdoor air temp IN6 Mixed-air temp IN7 Low temp detect IN8 Run/stop IN9 Occupancy (or generic) IN10 Supply fan status IN11 Filter status IN12 Exhaust fan status Duct static pressure connector Not used Termination board Comm5 terminals Jack for Rover service tool Main circuit board IN13 Space relative humidity, CO2 sensor, entering water temperature, or evaporator refrigerant temp 24 CNT-SVN02B-EN

Binary outputs Binary outputs The Tracer AH541 controller has six binary outputs that are normallyopen, form-a binary relays. The relays act as a switch by either completing 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 24 Vac Termination board Wiring external to the termination board BO1 GND Supply fan start/stop relay 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. CNT-SVN02B-EN 25

Chapter 6 Wiring inputs and outputs Wiring binary outputs IMPORTANT Use 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. 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 outputs in their product specifications. To wire a binary output: 1. Connect the common wire to a common terminal as shown in Figure 15. Note: Because the common terminals are in parallel, you can wire the common wire to any available common terminal. 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. Powered output Signal < 1000 ft (300 m) Common Pilot relay 24 Vac coil Tape back shield Signal Common < 1000 ft (300 m) 26 CNT-SVN02B-EN

Binary outputs Checking binary outputs IMPORTANT Perform the tests in this section before providing power to the termination 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 Avoid Equipment Damage! 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 resistance 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. For additional troubleshooting information, refer to the Tracer AH540 user guide, CNT-SVX05B-EN. CNT-SVN02B-EN 27

Chapter 6 Wiring inputs and outputs Figure 16. Example of wiring analog outputs Analog outputs The 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. Ac powered actuator 24 Vac Signal Common Tape back shield < 1000 ft (300 m) 0 10 Vdc output Load > 500 Ω Signal Common Tape back shield 28 CNT-SVN02B-EN

Analog outputs Checking analog outputs IMPORTANT Perform the tests in this section before providing power to the termination board or installing the main circuit board. Failure to do so will result in incorrect multi-meter readings. 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 connected. Check along the wire to make sure that no additional connections have been made. CAUTION Avoid Equipment Damage! Continue to step 4 only if you completed steps 2 and 3 successfully. Measuring resistance may damage the meter if the voltage is too high. 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.) For additional troubleshooting information, refer to the Tracer AH540 user guide, CNT-SVX05B-EN. CNT-SVN02B-EN 29

Chapter 6 Wiring inputs and outputs Zone sensor Table 8. Tracer zone temperature sensor options The Tracer AH541 controller supports the Trane zone temperature sensors listed in Table 8. BAS part number Auto Fan switch Zone Override buttons Off Setpoint thumbwheel Temperature sensor On Cancel Comm jack 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. 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 controller. When a user presses the On or Cancel button, the signal is temporarily 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 setpoint. 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 controller, 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. 30 CNT-SVN02B-EN

Zone sensor 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. Table 9. Screw terminals on a zone sensor Terminal Zone sensor with fan-mode switch Zone 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 present 1 Do not connect if Comm5 communications are not required at the zone sensor. Figure 17. Wiring the zone sensor 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. Fan mode Setpoint Common Space temp < 300 ft (100 m) Trane zone sensor CNT-SVN02B-EN 31

Chapter 6 Wiring inputs and outputs Checking the zone sensor inputs IMPORTANT Perform the tests in this section before providing power to the termination board or installing the main circuit board. Failure to do so will result in incorrect multi-meter readings. 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 Avoid Equipment Damage! Continue to step 4 only if you completed steps 2 and 3 successfully. Measuring resistance may damage the meter if the voltage is too high. 4. Set the multi-meter to measure resistance. If you completed steps 2 and 3 successfully, measure the resistance across the input at the signal 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). 32 CNT-SVN02B-EN

Analog inputs Analog inputs Analog 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) CO 2 sensor (current, 4 to 20mA) Entering water temperature (10 kω thermistor) Evaporator refrigerant temperature (10 kω thermistor) Generic temperature (10 kω thermistor) IMPORTANT The Tracer AH541 controller must receive a valid discharge-air temperature value to operate properly for all control modes. The sensor must be located at the discharge point downstream from all unit heating/cooling 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 economizing 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, CO 2 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 dehumidification control in SCC applications. Also an entering water temperature 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 evaporator 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. CNT-SVN02B-EN 33

Chapter 6 Wiring inputs and outputs If the universal analog input is configured for CO 2 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 Discharge-air temperature Purpose Part number Sensor type 4190 1103 4190 1110 4190 1111 4-inch thermistor 6-inch thermistor 12-inch thermistor Outdoor-air 4190 1101 Thermistor temperature Mixed-air temperature 4190 1119 385 platinum 24-foot duct-averaging RTD Space relative humidity CO 2 sensor 4190 4100 4190 4101 Entering water temperature 4190 7018 5% Room relative humidity (4 to 20 ma) & temperature sensor (thermistor) X39640722-01 Thermistor Current, 4 to 20 ma, wall mount Current, 4 to 20 ma, duct mount DX coil defrost sensor X39640722-01 Installation kit: Thermostat/thermistor suction line installation. 34 CNT-SVN02B-EN

Analog inputs Wiring analog inputs Figure 18. Wiring variable resistance analog inputs Variable resistance T Signal Common To wire the discharge-air temperature input, the outside-air temperature 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). < 300 ft (100 m) Temperature sensor Signal Common Tape back shield CNT-SVN02B-EN 35

Chapter 6 Wiring inputs and outputs Checking the discharge-air and outside-air temperature inputs IMPORTANT Perform the tests in this section before providing power to the termination board or installing the main circuit board. Failure to do so will result in incorrect multi-meter readings. To check the discharge-air and outside-air temperature inputs for proper operation: 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, temperature 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 0 Vdc. If the voltage is greater than this, temperature readings may be offset from the expected results. CAUTION Avoid Equipment Damage! Continue to step 4 only if you completed steps 2 and 3 successfully. Measuring resistance may damage the meter if the voltage is too high. 4. Set the multi-meter to measure resistance. If you completed steps 2 and 3 successfully, measure the resistance across the input at the signal and common screw terminals. 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 temperatures and resistances are shown in Table 11 on page 37. 36 CNT-SVN02B-EN

Analog inputs 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 For additional troubleshooting information, refer to the Tracer AH540 user guide, CNT-SVX05B-EN. CNT-SVN02B-EN 37

Chapter 6 Wiring inputs and outputs Checking the mixed-air temperature input IMPORTANT Perform the tests in this section before providing power to the termination board or installing the main circuit board. Failure to do so will result in incorrect multi-meter readings. To check the mixed-air temperature input for proper operation: 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, temperature 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, temperature readings may be offset. CAUTION Avoid Equipment Damage! Continue to step 4 only if you completed steps 2 and 3 successfully. Measuring resistance may damage the meter if the voltage is too high. 4. Set the multi-meter to measure resistance. If you completed steps 2 and 3 successfully, measure the resistance across the input at the signal and common screw terminals. 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 temperatures within this range. For additional troubleshooting information, refer to the Tracer AH540 user guide, CNT-SVX05B-EN. 38 CNT-SVN02B-EN

Analog inputs Wiring 4 20 ma analog inputs 4 20 ma analog inputs include humidity sensors and CO 2 sensors. 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. 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. CNT-SVN02B-EN 39

Chapter 6 Wiring inputs and outputs Figure 19. Wiring 4 20 ma analog inputs 24 Vdc i 4 20 ma out Common < 1000 ft (300 m) 4 20 ma sensor (current source) Tape back shield IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 i 24 Vdc 4 20 ma sensor (current controller) Tape back shield 4 20 ma out < 1000 ft (300 m) IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 40 CNT-SVN02B-EN

Binary inputs Binary inputs Binary 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. 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. 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. 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) disabled 1 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. Low temperature detection protects the coils of hydronic units. A low temperature 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 CNT-SVN02B-EN 41