Installing the Tracer ZN517 Unitary Controller Ordering number: ,

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1 Installing the Tracer ZN517 Unitary Controller Ordering number: , Product overview The Tracer ZN517 controller is a field-installed, application-specific controller that provides directdigital zone control. The controller can operate as a stand-alone device or as part of a building automation system (BAS). The Tracer ZN517 is designed to control the following types of equipment: 2-heat/2-cool rooftop unit with optional economizer control 4-cool rooftop unit with optional economizer control 2-compressor heat pump with optional economizer and auxiliary heat control Split system The Tracer ZN517 follows the guidelines of the LonMark Space Comfort Controller (SCC) profile. The Tracer ZN517 is available in two different versions: frame-mount ( ) and metal enclosure ( ). (See Figure 3 and Figure 4 on page 3.) The frame-mount package contains: A Tracer ZN517 circuit board fastened to a metal back plate A removable molded resin cover The metal-enclosure package contains: A Tracer ZN517 circuit board fastened to the back piece of the metal enclosure A removable metal cover Shipment Visually inspect all parts for obvious defects or damage. All components are thoroughly inspected before leaving the factory. Any claims for damage incurred in shipping should be filed with the carrier. Storage environment An indoor storage environment is recommended that meets the following requirements: Temperature: 40 F to 185 F ( 40 C to 85 C) Relative humidity: 5 95%, noncondensing Operating environment Make sure that the operating environment conforms to the specifications listed in Table 1. Dimensions and clearances are illustrated in Figure 1 and Figure 2 on page 2: Table 1. Operating environment specifications Temperature Humidity Power Mounting weight (framemount) Mounting weight (metal enclosure) From 40 F to 160 F ( 40 C to 70 C) 5 90%, noncondensing Vac (24 Vac nominal), Hz 9 VA per controller and a maximum of 12 VA per output utilized Mounting surface must be able to support 2 lb (1 kg) Mounting surface must be able to support 8 lb (4 kg) Altitude 6,500 ft (2,000 m) Installation Category 3 Pollution Degree 2 Location For most applications, the Tracer ZN517 can be installed within the unit it is controlling. It is suitable for extended ambient s. If installed in an outdoor environment, it must be fully enclosed for protection from the elements. Trane also recommends locating the Tracer ZN517 unitary controller: Where public access is restricted to minimize the possibility of tampering or vandalism In or near the controlled piece of equipment to reduce wiring costs Where it is easily accessible for service personnel Trane A Business of American Standard Companies American Standard All rights reserved D

2 Figure 1. Dimensions and clearances for the frame-mount controller 1 in. (25 mm) in. (160 mm) 2 in. (51 mm) 4 in. (102 mm) AC POWER AC OUT OPN CLS ECONOMIZER Rc Rh G NO 5COM HVAC UNIT 5NC BINARY OUTPUT STATUS LED 4 in. (102 mm) in. (137 mm) 4 in. (102 mm) in. (175 mm) SERVICE LED PIN COMM5 BINARY INPUTS A B A B -BI1- -BI ANALOG INPUTS AI1 -AI2 - -DAT- ZONE SENSOR COMM5 ZN SET LED in. (143 mm) Clearances Dimensions 1 in. (25 mm) Figure 2. Dimensions and clearances for the metal-enclosure controller 1 in. (25 mm) in. (48 mm) 6.5 in. (165 mm) 2 in. (51mm) 9 in. (229 mm) 2 in. (51 mm) 7 in. (178 mm) 9 in. (229 mm) 24 in. (610 mm) in. (263 mm) width with cover 1 in. (25 mm) 2.25 in. (58 mm) 1 in. (25 mm) in. (260 mm) width without cover Clearances Dimensions D 2

3 Mounting the frame-mount controller IMPORTANT Mount the Tracer ZN517 controller with the cover on to avoid damaging the circuit board during installation. To mount the frame-mount controller: 1. Using the module as a template, mark the location of the two mounting holes on the mounting surface (Figure 3). 2. Set the module 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 module to the mounting surface with #10 (5 mm) screws (not included). Attach the frame-mount module securely so that it can withstand the vibrations of associated heating, ventilating, and air-conditioning (HVAC) equipment. Mounting the metal-enclosure controller To mount the metal-enclosure controller: 1. Remove the two cover screws and then the cover. 2. Using the enclosure as a template, mark the location of the four mounting holes on the mounting surface (Figure 4). 3. 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. 4. Insert wall anchors if needed. 5. Secure the enclosure to the mounting surface with #10 (5 mm) screws (not included). Figure 4. Mounting the metal-enclosure Tracer ZN517 controller Figure 3. Mounting the frame-mount Tracer ZN517 zone controller Agency conformance CE marked UL and C-UL listed: 916, Energy management equipment UL 94-5V (UL flammability rating for plenum use) FCC Part 15, Class A, CFR D

4 Configuring for equipment type Set the DIP switches on the Tracer ZN517 circuit board for the type of equipment that is going to be controlled. See Table 2 for DIP switch settings for each type of equipment. Table 2. DIP switch settings Equipment type (not used) Heating: 71.0 F (21.7 C) Cooling: 74.0 F (23.3 C) In unoccupied mode, the controller will operate at: Heating: 60.0 F (15.6 C) Cooling: 85.0 F (29.4 C) Inputs and outputs. For individual input and output factory defaults, See Tables 3, 4, and 5. 2-heat/2-cool (default) Off Off Off N/A Table 3. Binary inputs 2-heat/2-cool w/economizer Off Off On N/A Binary input Functions Defaults Rating 4-cool On Off Off N/A 4-cool w/economizer On Off On N/A Heat pump Off On Off N/A Heat pump w/economizer Off On On N/A Invalid On On Off N/A Invalid On On On N/A ON DIP Factory defaults 2-heat/2-cool (default) The Tracer ZN517 controller is shipped with the following default settings. To change defaults, use DIP switches, a Rover service tool, or a BAS, as appropriate. Equipment type. The Tracer ZN517 ships from the factory configured to control a 2-heat/2-cool rooftop unit without economizer. To change this configuration, see Configuring for equipment type. Setpoints. In occupied mode, the controller can receive a setpoint from either a zone sensor (default) or from a BAS. If neither a zone sensor value or a communicated value is received, the Tracer ZN517 will operate at the following default setpoints: BI1 Occupancy or generic Occupancy Volt-free dry contact BI2 Fan status Fan status Volt-free dry contact Note: Do not apply power to these inputs. Table 4. Analog inputs Analog input AI1 AI2 DAT ZN SET Functions Defaults Rating Generic, RH, CO 2, or not used Outdoor air or generic Discharge air Zone Temperature setpoint Not used Generic Discharge air Zone Zone setpoint 10,000 Ω at 77 F (25 C) 10,000 Ω at 77 F (25 C) 10,000 Ω at 77 F (25 C) 10,000 Ω at 77 F (25 C) 1000 Ω potentiometer Note: For best results and accuracy, use only Trane sensors D 4

5 Table 5. Binary outputs Binary output 2-heat/ 2-cool 4-cool Heat pump Rating OPN Economizer, drive open Economizer, drive open Economizer, drive open Triac, 24 Vac, max 500 ma, min 50 ma CLS Economizer, drive closed Economizer, drive closed Economizer, drive closed Triac, 24 Vac, max 500 ma, min 50 ma Rc 24 Vac from HVAC system 24 Vac from HVAC system 24 Vac from HVAC system 24 Vac nominal Rh 24 Vac from HVAC system 24 Vac from HVAC system 24 Vac from HVAC system 24 Vac nominal G Supply fan Supply fan Supply fan Form A relay, powered contact, 24 Vac, 1 A max 1 Cool stage 1 (Y 1 ) Cool stage 1(Y 1 ) Compressor 1(Y 1 ) Form A relay, powered contact, 24 Vac, 1 A max 2 Cool stage 2 (Y 2 ) Cool stage 2 (Y 2 ) Compressor 2 (Y 2 ) Form A relay, powered contact, 24 Vac, 1 A max 3 Heat stage 1 (W 1 ) Cool stage 3 (Y 3 ) Reversing valve (O) Form A relay, powered contact, 24 Vac, 1 A max 4 Heat stage 2 (W 2 ) Cool stage 4 (Y 4 ) Auxiliary heat (W 1 ) Form A relay, powered contact, 24 Vac, 1 A max 5NO/ Exhaust fan*/generic/ Exhaust fan*/generic/ Exhaust fan*/generic/ Form C relay, pow 5COM/ occupancy occupancy occupancy ered contact, 24 Vac, 5NC 1 A max *Factory default AC-power wiring See Figure 5 on page 6 or Figure 6 on page 6 for the location of the ac-power connections. IMPORTANT Make sure that the 24 Vac power supplies are consistently grounded. Do not share 24 Vac between controllers. The recommended wire for ac power is 16 AWG copper wire. All wiring must comply with National Electrical Code and local codes. If you are providing a new transformer for power, use a UL-listed Class 2 power transformer supplying a nominal 24 Vac (19 30 Vac). The transformer must be sized to provide adequate power to the Tracer ZN521 zone controller (14 VA) and output devices, including relays and valve actuators (a maximum of 12 VA per output utilized). Please read the warning and cautions before proceeding. WARNING Hazardous voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. CAUTION Injury and equipment damage! Make sure that the 24 Vac transformer is properly grounded. Failure to do so may result in personal injury and/or damage to equipment D

6 A B A B Rh 2 CAUTION Equipment damage! Complete input/output wiring before applying power to the controller. Failure to do so may cause damage to the controller or power transformer due to inadvertent connections to power circuits. Do not share 24 Vac between controllers. Failure to do so may cause controller damage. Wiring AC-power to the frame-mount controller Please read the preceding warning and cautions. To connect ac-power to the frame-mount controller: 1. Connect the ground wire from the 24 Vac transformer to the terminal shown in Figure Connect the power wire to the terminal. Figure 5. AC-power wiring for frame-mount 24 Vac transformer N H AC POWER AC OUT Wiring AC-power to the metal-enclosure controller Please read the preceding warnings and cautions. To connect ac-power wiring to the enclosure: 1. Remove the cover of the enclosure. 2. Remove the knockout for the 0.5 in. (13 mm) conduit from the enclosure and attach the conduit. 3. Feed the power wire into the enclosure. 4. When mounting on dry wall or other non-conductive surface, connect an earth ground to the earth-ground screw on the enclosure (Figure 6). 5. Connect the ground wire from the 24 Vac transformer to the terminal shown in Figure Connect the power wire to the terminal. 7. Replace the cover of the enclosure. Figure 6. AC-power wiring for metal enclosure SERVICE LED PIN COMM5 BINARY INPUTS ANALOG INPUTS ZONE SENSOR COMM5 -BI1 -BI2 +20 AI1 -AI2- -DAT- ZN SET LED Communication-link wiring OPN CLS Rc AC POWER AC OUT ECONOMIZER HVAC UNIT BINARY OUTPUT G NO 5COM 5NC LED AC POWER Ground screw The Tracer ZN517 communicates with the building automation system (BAS) and with other controllers by means of a Comm5 communication link. Comm5 is Trane s implementation of LonTalk. For instructions on Comm5 communication wiring and addressing, follow the Tracer Summit Hardware and Software Installation guide (BMTX-SVN01A), the Tracker Building Automation System Hardware Installation guide (BMTK-SVN01D), or another BAS installation manual. HVAC unit electrical circuit wiring The terminals labeled Rc and Rh are provided as inputs for 24 Vac power from the transformer(s) of the HVAC system. Note: The Tracer ZN517 is shipped from the factory with terminals Rc and Rh coupled with a jumper at J1 on the controller circuit board. Packaged units If the HVAC unit combines heating and cooling (referred to as a packaged unit), it will typically have one R transformer. For 24 Vac wiring of packaged units, the Rc terminal must be wired as shown in this procedure: 1. Locate the jumper at J1 on the controller circuit board (Figure 7 on page 7). Place the jumper on both pins at J1 on the circuit board (Figure 8 on page 7). 2. Wire the Rc terminal to the transformer on the unit (Figure 9 on page 8) D 6

7 Split systems If the unit is a split system (a unit with physically separate heating and cooling sections), there is typically a separate transformer for each function. For 24 Vac wiring of split systems, the Rc and Rh terminals must be wired as shown in this procedure: Figure 8. Coupling and uncoupling terminals Rc and Rh for 24 Vac wiring of the HVAC unit For packaged units Place the jumper on both pins at J1. J1 1. Locate the jumper at J1 on the controller circuit board (Figure 7). Remove the jumper from the pins at J1 on the circuit board (Figure 8). 2. Replace the jumper on one of the pins at J1 for possible future use. 3. Wire Rc to the transformer for the cooling section of the unit (Figure 10 on page 8). 4. Wire Rh to the transformer for the heating section of the unit (Figure 10 on page 8). Figure 7. Location of J1 on Tracer ZN517 circuit board For split systems Remove the jumper from the pins at J1. (Replace the jumper on one of the pins for possible future use.) J1 J1 (location of jumper for Rc, Rh terminals) D

8 Figure 9. Wiring for packaged heating and cooling units Primary Secondary, 24 Vac Tri-state modulating economizer Fan Compressor 1 contactor Compressor 2 contactor Heat stage 1 24 Vac H N R G Y1 Y2 Heat stage 2 W1 W2 Generic binary output OPN CLS AC POWER AC OUT ECONOMIZER Rc Rh G NO 5COM 5NC HVAC UNIT BINARY OUTPUT STATUS LED Figure 10. Wiring for split system applications Primary Secondary, 24 Vac Primary Secondary, 24 Vac Tri-state modulating economizer Fan* Compressor 1 contactor Compressor 2 contactor Heat stage 1 24 Vac H N Rc Rh G Y1 Y2 W1 W2 Heat stage 2 Generic binary output OPN CLS AC POWER AC OUT ECONOMIZER Rc Rh G NO 5COM 5NC HVAC UNIT BINARY OUTPUT STATUS LED *Wire the fan (G) to the appropriate section of the split system. Input/Output terminal wiring All input/output terminal wiring for the Tracer ZN517 unitary controller is application specific. Input/output terminal wiring must meet the following requirements: All wiring must be in accordance with the National Electrical Code and local codes. Use only AWG, stranded, tinned-copper, shielded, twisted-pair wire. Binary input and output wiring should be a maximum length of 300 ft (100 m). Analog input wiring should be a maximum length of 300 ft (100 m). Do not run input/output wires in the same wire bundle with any ac power wires D 8

9 Binary inputs, binary outputs, and analog inputs are identified by label and function in Table 3 on page 4, Table 5 on page 5, and Table 4 on page 4, respectively. Figure 11. Wiring diagram for the 2-heat/2-cool application See example wiring diagrams that include all required and optional components for: 2-heat/2-cool applications (Figure 11 on page 9) 4-cool applications (Figure 12 on page 10) Heat pump applications (Figure 13 on page 11) Power* Tri-state modulating economizer Fan Compressor 1 contactor Compressor 2 contactor Heat stage 1 24 Vac H N R G Y1 Y2 W1 W2 Heat stage 2 Generic binary output Comm5 In Out *Terminals Rc and Rh are provided as inputs for 24 Vac power from the controlled device. If the device has a separate heating and cooling units, use Rh Occupancy or generic for heat and Rc for cooling. If combined, use only Rc (see HVAC unit electrical circuit wiring on page 6). Dry contacts only Typical 3-wire sensor Fan status (default: closed = no flow open = flow) Discharge air Outdoor air Comm D

10 Figure 12. Wiring diagram for the 4-cool application Power* Tri-state modulating economizer Fan Compressor 1 contactor Compressor 2 contactor Compressor 3 contactor 24 Vac H N R G Y1 Y2 Y3 Y4 Compressor 4 contactor Generic binary output Comm5 In Out *Terminals Rc and Rh are provided as inputs for 24 Vac power from the controlled device. If the device has a separate heating and cooling units, use Rh for heat and Rc for cooling. If combined, use only Rc (see HVAC unit electrical circuit wiring on page 6). Occupancy or generic Dry contacts only Typical 3-wire sensor Fan status (default: closed = no flow open = flow) Discharge air Outdoor air Comm D 10

11 Figure 13. Wiring diagram for the heat pump application Power* Tri-state modulating economizer Fan Compressor 1 contactor Compressor 2 contactor Reversing valve 24 Vac H N R G Y1 Y2 O W1 Auxiliary heat Generic binary output Comm5 In Out *Terminals Rc and Rh are provided as inputs for 24 Vac power from the controlled device. If the device has a separate heating and cooling units, use Rh for heat and Rc for cooling. If combined, use only Rc (see HVAC unit electrical circuit wiring on page 6). Occupancy or generic Dry contacts only Typical 3-wire sensor Fan status (default: closed = no flow open = flow) Discharge air Outdoor air Comm5 The following are trademarks or registered trademarks of American Standard Inc.:Tracer, Tracer Summit, Trane. The following are trademarks or registered trademarks of their respective companies or organizations: LonTalk from Echelon Corporation, National Electrical Code from the National Fire Protection Association D

12 Declaration of Conformity Manufacturer s Name: Manufacturer s Address: The manufacturer hereby declares that the product Product Name: Model Number: Conforms to the following standards or other normative documents: Electromagnetic Emission: (by Council Directive 89/336/EEC) Trane 4833 White Bear Parkway St. Paul MN USA Unitary Controller ZN517 ( and ) EN :1992 EN :1995 EN :1995 Radiated EN55011:1999 Conducted EN55011:1999 Class B limit: Class A limit: Class B limit: Class B limit: Electromagnetic Immunity: (by Council Directive 89/336/EEC) EN :1995 EN :1999 IEC :1995 EN IEC :1995 EN :1996 Amendment A1:1998 IEC :1995 EN IEC :1995 EN IEC :1996 EN IEC :1993 EN IEC :1994 EN ±4.0 kv by contact 10.0 V/m MHz ±1.0 kv signal lines ±2.0 kv ac power lines ±2.0 kv ac power lines 10 V MHz 30 A/m When and Where Issued Electromagnetic Emission 12/27/2001 Electromagnetic Immunity 12/27/2001 Mark of Compliance John Olson, Design/Compliance Engineer European Contact Societe Trane (Epinal, France) 1, rue des Ameriques, B.P. 6 F Golbey Cedex, France Phone: (33) Fax: (33) This document validates CE conformity of the European unitary controller, ZN D 12