Installing the Tracer™ ZN517 Unitary Controller Ordering number: 4950 0496, 4950 0596

Product overview The Tracer ZN517 controller is a field-installed, application-specific controller that provides direct-digital zone temperature 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 (4950 0496) and metal enclosure (4950 0596). (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 From –40°F to 160°F (–40°C to 70°C)

Humidity 5–90%, noncondensing

Power

19–30 Vac (24 Vac nominal), 50–60 Hz

9 VA per controller and a maximum of 12 VA per output utilized

Mounting Mounting surface must be able to weight (frame- support 2 lb (1 kg) mount)

Mounting Mounting surface must be able to weight (metal support 8 lb (4 kg) enclosure)

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 temperatures. 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 www.trane.com © 2005 American Standard All rights reserved 3270 3351 D

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Figure 1. Dimensions and clearances for the frame-mount controller

Figure 2. Dimensions and clearances for the metal-enclosure controller

LEDA BBA +20GND-BI2- SET-BI1- ZNLED GNDPIN

ZONE SENSORZONE SENSOR

SERVICE

ANALOG INPUTSANALOG INPUTSCOMM5

COMM5

24VGND

HVAC UNITHVAC UNIT

RhRc 1G 432 5NO5COM

LED

STATUS5NC

BINARY INPUTS

AI1 -DAT-

24VGND GND 24V OPN CLS

BINARY OUTPUTECONOMIZERAC OUTAC OUTAC POWERAC POWER

-AI --AI -2

2 in. (51 mm)

Clearances

Dimensions

6.875 in.(175 mm)

6.313 in.(160 mm)

5.375 in.(137 mm)

5.625 in. (143 mm)

1 in.(25 mm)

4 in.(102 mm)

4 in.(102 mm)

4 in.(102 mm)

1 in.(25 mm)

Clearances

Dimensions

9 in.(229 mm)

10.37 in.(263 mm)

width with cover

2.25 in.(58 mm)

7 in.(178 mm)

1 in.(25 mm)

1.875 in.(48 mm)

6.5 in.(165 mm)

9 in.(229 mm)

10.25 in.(260 mm)

width without cover

24 in.(610 mm)

1 in.(25 mm)

1 in.(25 mm)

2 in.(51 mm)

2 in.(51mm)

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Mounting the frame-mount controller

IMPORTANTMount 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 loca-tion 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.

Figure 3. Mounting the frame-mount Tracer ZN517

zone controller

Mounting the metal-enclosure controllerTo 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

Agency conformanceCE 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 47

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

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)

Equipment

type 1 2 3

4

(not

used)

2-heat/2-cool (default)

Off Off Off N/A

2-heat/2-cool w/economizer

Off Off On N/A

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

• Inputs and outputs. For individual input and output factory defaults, See Tables 3, 4, and 5.

Table 3. Binary inputs

Binary

input Functions Defaults Rating

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

1 2 3 4

O N D I P

2-heat/2-cool (default)

Factory defaults 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:

Analog

input Functions Defaults Rating

AI1 Generic, RH, CO2, or not used

Not used 10,000 Ω at 77°F (25°C)

AI2 Outdoor air temperature or generic

Generic 10,000 Ω at 77°F (25°C)

DAT Discharge air temperature

Discharge air temperature

10,000 Ω at 77°F (25°C)

ZN Zone tempera­ture

Zone temperature

10,000 Ω at 77°F (25°C)

SET Temperature setpoint

Zone temperature setpoint

1000 Ω potentiometer

Note: For best results and accuracy, use only Trane temperature sensors.

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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 (optional) (optional) (optional)

G Supply fan Supply fan Supply fan Form A relay, pow­ered contact, 24 Vac, 1 A max

1 Cool stage 1 (Y1) Cool stage 1(Y1) Compressor 1(Y1) Form A relay, pow­ered contact, 24 Vac, 1 A max

2 Cool stage 2 (Y2) Cool stage 2 (Y2) Compressor 2 (Y2) Form A relay, pow­ered contact, 24 Vac, 1 A max

3 Heat stage 1 (W1) Cool stage 3 (Y3) Reversing valve (O) Form A relay, pow­ered contact, 24 Vac, 1 A max

4 Heat stage 2 (W2) Cool stage 4 (Y4) Auxiliary heat (W1) Form A relay, pow­ered contact, 24 Vac, 1 A max

5NO/ Exhaust fan*/generic/ Exhaust fan*/generic/ Exhaust fan*/generic/ Form C relay, pow­5COM/ 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.

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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 GND terminal shown in Figure 5.

2. Connect the power wire to the 24V terminal.

Figure 5. AC-power wiring for frame-mount

24 Vactransformer

24VGND 24VGND

AC OUTAC OUTAC POWERAC POWER

H N

Figure 6. AC-power wiring for metal enclosure

5C

OM

BIN

AR

Y O

UT

PU

T

LE

D

5N

C3

4

5N

O2

G

1

HV

AC

UN

IT

24V

AC

OU

T

OP

N

EC

ON

OM

IZE

R

Rh

CL

S

Rc

GN

D2

4V

GN

D

AC

PO

WE

R G

ND

24V

GN

D

ZO

NE

SE

NS

OR

CO

MM

5

LE

D

ZN

S

ET

GN

D

AN

AL

OG

INP

UT

S

-AI2

--D

AT

-+

20

A

I1B

CO

MM

5

-BI1

­

BIN

AR

Y IN

PU

TS

-BI2

­B

A

SE

RV

ICE

A

P

INL

ED

24

V2

4V

GN

DG

ND

AC

PO

WE

RA

CP

OW

ER

Ground screw

Communication-link wiring 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.

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-conduc-tive 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 GND terminal shown in Figure 6.

6. Connect the power wire to the 24V terminal.

7. Replace the cover of the enclosure.

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).

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7 3270 3351 D

Split systemsIf 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:

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 sec-tion of the unit (Figure 10 on page 8).

4. Wire Rh to the transformer for the heating sec-tion of the unit (Figure 10 on page 8).

Figure 7. Location of J1 on Tracer ZN517 circuit

board

Figure 8. Coupling and uncoupling terminals Rc

and Rh for 24 Vac wiring of the HVAC unit

J1 (location of jumper for Rc, Rh terminals)

Place the jumper on both pins at J1.

Remove the jumper from the pins at J1. (Replace the jumper on one of the pins for possible future use.)

J1

J1

For packaged units

For split systems

Figure 9. Wiring for packaged heating and cooling units

24V24VGNDGND

HVAC UNITHVAC UNIT

RhRc 1G 432 5NO5NO5COM

LEDLED

STATUS5NC5NC24V24VGNDGND GNDGND 24V24V OPNOPN CLS

BINARY OUTPUTBINARY OUTPUTECONOMIZERECONOMIZERAC OUTAC OUTAC POWERAC POWER

Compressor 1 contactor

Heat stage 1

Tri-state modulating economizer (optional)

Fan

H N

24 Vac

Generic binary output (optional)

Compressor 2 contactor

Heat stage 2

Primary

Secondary, 24 Vac

G Y1 Y2R W1 W2

Figure 10. Wiring for split system applications

*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.

24V24VGNDGND

HVAC UNITHVAC UNIT

RhRc 1G 432 5NO5NO5COM

LEDLED

STATUS5NC5NC24V24VGNDGND GNDGND 24V24V OPNOPN CLS

BINARY OUTPUTBINARY OUTPUTECONOMIZERECONOMIZERAC OUTAC OUTAC POWERAC POWER

Compressor 1 contactor

Heat stage 1

Tri-state modulating economizer (optional)

Fan*

H N

24 Vac

Generic binary output (optional)

Compressor 2 contactor

Heat stage 2

Primary

Secondary, 24 Vac

G Y1 Y2Rc W1 W2

Primary

Secondary, 24 Vac

Rh

• Use only 18–22 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.

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9 3270 3351 D

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.

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)

Figure 11. Wiring diagram for the 2-heat/2-cool application

Compressor 1 contactor

Heat stage 1

Tri-state modulating economizer (optional)

Fan

HN

24 Vac

Generic binary output (optional)

Compressor 2 contactor

G Y2

Heat stage 2

Power*

R W2W1Y1

Comm5

Occupancyor generic(optional)

Typical 3-wire sensor

(optional)

Comm5

In

OutDischarge air temperature

Outdoor air temperature (optional)

*Terminals Rc and Rh are provided as inputs for 24 Vac power from the con-trolled device. If the device has a sepa-rate 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).

Dry contacts only

Fan status(default: closed = no flowopen = flow)(optional)

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Figure 12. Wiring diagram for the 4-cool application

Comm5

In

Outdoor air temperature (optional)

Discharge airtemperature Comm5

Out

Compressor 1 contactor

Compressor 3 contactor

Tri-state modulating economizer (optional)

Fan

HN

24 Vac

Generic binary output (optional)

Compressor 2 contactor

G Y2

Compressor 4 contactor

Power*

R Y4

Typical 3-wire sensor

(optional)

Occupancy or generic (optional)

Y1 Y3

*Terminals Rc and Rh are provided as inputs for 24 Vac power from the con-trolled device. If the device has a sepa-rate heating and cooling units, use Rh for heat and Rc for cooling. If com-bined, use only Rc (see “HVAC unit electrical circuit wiring” on page 6).

Dry contacts only

Fan status(default: closed = no flowopen = flow)(optional)

11 3270 3351 D

Figure 13. Wiring diagram for the heat pump application

*Terminals Rc and Rh are provided as inputs for 24 Vac power from the con-trolled device. If the device has a sepa-rate heating and cooling units, use Rh for heat and Rc for cooling. If com-bined, use only Rc (see “HVAC unit electrical circuit wiring” on page 6).

Comm5

In

Out

Occupancy or generic (optional)

Compressor 1 contactor

Reversing valve

Tri-state modulating economizer (optional)

Fan

HN

24 Vac

Generic binary output (optional)

Compressor 2 contactor

G

Auxiliary heat

Power*

R O W1Y2

Discharge airtemperature Comm5

Typical 3-wire sensor

(optional)

Outdoor air temperature (optional)

Y1

Dry contacts only

Fan status(default: closed = no flowopen = flow)(optional)

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.

™ ®

™ ®

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)

Electromagnetic Immunity:

(by Council Directive 89/336/EEC)

When and Where Issued

Electromagnetic Emission 12/27/2001 Electromagnetic Immunity 12/27/2001

Mark of Compliance

Trane 4833 White Bear Parkway St. Paul MN 55110 USA

Unitary Controller ZN517 (4950 0496 and 4950 0596)

EN50081-1:1992 EN61000-3-2:1995 EN6100-3-3:1995 Radiated EN55011:1999

Conducted EN55011:1999

EN50082-2:1995 EN61000-6-2:1999 IEC 1000-4-2:1995 EN61000-4-2

IEC 1000-4-3:1995 EN61000-4-3:1996 Amendment A1:1998

IEC 1000-4-4:1995 EN61000-4-4

IEC 1000-4-5:1995 EN61000-4-5

IEC 1000-4-6:1996 EN61000-4-6

IEC 1000-4-8:1993 EN61000-4-8

IEC 1000-4-11:1994 EN61000-4-11

Class B limit: 4950 0496 Class A limit: 4950 0596 Class B limit: 4950 0496 Class B limit: 4950 0596

±4.0 kV by contact

10.0 V/m80 .. 1000 MHz

±1.0 kV signal lines ±2.0 kV ac power lines

±2.0 kV ac power lines

10 V 0.15 .. 80 MHz

30 A/m

John Olson, Design/Compliance Engineer

European Contact

Societe Trane (Epinal, France) 1, rue des Ameriques, B.P. 6 F-88191 Golbey Cedex, France Phone: (33) 329.31.73.00 Fax: (33) 329.81.24.98

This document validates CE conformity of the European unitary controller, ZN517.

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