WSHP-IOP-2
May 1998
Installation, Operation,
and Programming
Tracer™ ZN510 Controller
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Table of Contents
Start-up Procedure
Power-up Sequence
Unit Identification Tag
4
5
6
Unit Operation
General Information
Communication
Power
7
7
7
8
Binary Outputs
Analog Outputs
Binary Inputs
8
9
9
Analog Inputs
12
Zone Sensors
15
Heating or Cooling Control
Mode Operation
Single or Dual Compressor
Operation
18
19
Data Sharing
Configuration
20
21
22
27
28
29
31
33
Troubleshooting
Diagnostics
ZN510 Controller Replacement
Wiring Diagram
Hardware Specifications
Appendix
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Start-up
Procedure
Installation of New Units
1. Follow all instruction for
installation of water source
heat pumps as detailed in the
IOM (Installation Operation
Maintenance manual).
5. Verify that water connections
have been made to unit, then
ensure that water is circulating
through the unit.
6. Reapply power.
2. Disconnect power or disable
7. Check for STATUS GREEN LED
operation to ensure power and
communication has been made
the circuit breaker to unit.
™
3. Run communication link wire to
field terminal strips 14 and 16.
(See wiring diagram in the
unit).
to the ZN510 .
Peel IDENTIFICATION TAG from unit
and place in the ZN510 IOP, on a
copy of Sheet 6 of this document, or
on building plans for future location
use. The actual room location on the
tag may be hand written.
4. Install zone sensor to low
voltage control terminals 1
through 6. (See wiring diagram
in the unit and zone sensor
submittals).
Zone Sensor Placement
Zone sensor location is an important
element of effective room control
and comfort.
The following are typical areas
where the zone sensor should not
be mounted:
z Near drafts or “dead spots”
The best sensor location is typically
on a wall, remote from the HVAC unit.
Readings at this location assure that
the desired setpoint is achieved
across the space, not just near the
unit itself. It may be necessary to
subdivide the zone with multiple
units to ensure adequate control
and comfort.
(e.g., behind doors or corners)
z Near hot or cold air ducts
z Near radiant heat (e.g., heat
emitted from appliances or the
sun)
z Near concealed pipes or
chimneys
z On outside walls or other non-
conditioned surfaces
z In air flows from adjacent zones
or other units
4
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Power Up
Sequence
Power Up Sequence
3. A random start time is hard
coded on every board and
cannot be disabled. The board
generates a random time delay
between 0 and 25 seconds.
Once this time expires, the
power up control wait time (if
configured) will wait for 120
seconds. The power up control
wait allows ample time for a
communicated request to
arrive. If the power up control
wait time expires, and the
controller does not receive a
communicated occupancy
command, the unit assumes
stand alone operation.
When 24 VAC power initially is
applied to the ZN510 controller, the
following sequence occurs:
1. All outputs are controlled off.
2. The controller reads all inputs
to determine their initial values.
Note: Because the space tempera-
ture can be hardwired to the con-
troller or communicated, the
controller waits for several minutes
to check for the presence of a com-
municated value.
4. Normal operation begins.
5
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Unit
Identification
Tag
Unit Identification Tag
The unit identification tag is factory
mounted and provided for easy
identification of an installed unit. It
contains model number, tagging,
and location information. See
Figure 1.
The top portion of the unit
identification tag remains
permanently affixed to the unit for
identity purposes. The bottom
portion of the tag provides pertinent
information that is removable to be
placed on building plans or in the
ZN510 IOP on page 33. This provides
identification history about the unit’s
location for quick reference.
These tags provide information
about unit location, unit serial
number, and NID (neuron
identification number). The NID is
similar to the serial number of the
unit but is specific to the
identification of the ZN510 Board.
The location identification is a
customer defined, clear English
description, of the unit’s physical
location. This is a 27 character
description of the location. For
example, if the location identification
for a unit is “Conference Room 101”,
the ZN510 and Rover (the Trane
Comm 5 service tool) will recognize
this clear English description so
maintenance can be performed on
the appropriate unit. If location
identification is not defined, it will
default to the unit serial number. This
provides some information so the
user has multiple references to the
unit. The blank location is provided
for field modification in case the unit
is moved from the initial location.
Figure 1: Unit Identification Tag
Note: Fold and tear carefully along dashed
removable line.
6
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Unit Operation
General Information
The ZN510 controller is a
z Console water source heat
z Up to two compressors.
pumps.
z Reversing valve.
microprocessor-based direct digital
controller that controls a variety of
water source heat pump equipment
including:
z Standard efficiency horizontal
and vertical units up to 10 tons.
ZN510 is designed to provide
accurate and reliable zone
temperature control by using
custom proportional integral (PI)
algorithms. The controller is factory
installed and configured to support:
z 2-position outdoor air damper
or generic binary output.
Peer-to-peer communication across
controllers is possible even when a
building automation system is not
present. ZN510 is also adaptable as
a standalone system.
z High efficiency horizontal and
z Single fan speed.
vertical units.
Figure 2: Communication connections
Communication
are provided for direct con-
nection of Rover to the ZN510
Board or provided as spare ter-
minals.
z Two terminals (TB2-5, TB2-6)
are connected to the field
terminal strip (1TB1-5, 1TB1-6)
which should be connected to
the zone sensor communication
jack. This provides direct
The ZN510 controller communicates
via Trane’s Comm5 protocol.
Typically, a communication link is
applied between unit controllers and
a building automation system.
Communication is also possible
z Two terminals (TB2-3, TB2-4)
are connected to the field
terminal strip (1TB1-14,
1TB1-16) for connection to the
communication link (daisy
chain).
connect of Rover to the commu-
nication link without having to
connect directly to the ZN510
board or provided as spare ter-
minals.
™
with Trane’s service tool Rover .
ZN510 provides a total of six 1/4-inch
quick-connect terminals for
connection to the Comm5
communication link. These
connections include:
z The field terminal strip 1TB1
provides screw terminations for
all field connections.
z Two terminals (TB2-1, TB2-2)
COMM
COMM
COMM
Space
Communication
Connection
20 pole low voltage
terminal strip screw
connections for
field hook-up
Zone
Sensor
Communication
Link
Figure 3: Communication Wiring
7
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Unit Operation
Power
Factory Supplied Transformer
The ZN510 controller is powered by 24
VAC. A total of two 1/4-inch quick-
connect terminals are provided for 24
VAC connection to the board. See
Figure 4 for ZN510 power requirement.
Line
Voltage
24VAC
Note: Power for field installed ancil-
lary devices is not available from the
board. It must be tapped at trans-
former. See Table 21 for excess power
available.
Figure 4: Power Connections
Binary Outputs
The ZN510 uses five of its binary
outputs to control heat pump units.
Outputs are load side switching triacs.
The triac acts as a switch by either
making or breaking the circuit
between the load (reversing valve,
damper, contactor, relay) and ground.
Field installed
2 position
damper actuator
24VAC
1TB1-17
See Figure 5 for the configuration of
the five binary outputs.
1TB1-18
2-Position Damper Actuator or
Generic Binary Output
Binary output 6 (BOP 6) is factory
configured to control a normally
closed 2-position outdoor air damper.
It may be field modified to control a
generic output for control by a
building automation system. If set up
as a generic output, the controller
does not use BOP 6 as part of the
normal control. A building automation
system must issue commands to
control the generic binary output.
Binary Outputs
Figure 5: Binary outputs
.
Note:
Table 1: BOP 6 control of a 2-position outdoor air damper
z During occupied mode, the
outdoor air damper is closed
when the fan is controlled off.
Model
Occupied
Fan Operation
Outdoor Air Damper
On or cycling
Open
Off
Closed
Closed
z During unoccupied mode, the
outdoor air damper normally
remains closed.
Occupied warm up or
cool down
On or cycling
Occupied standby
Unoccupied
On or cycling
Cycling
Closed
Closed
Closed
z 2-position damper must not
exceed 10 VA power output from
board.
Diagnostic present
Diagnostic dependent
8
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Unit Operation
Output Overrides
z Force compressor operation,
allowing the technician to use
refrigerant gauges or other test
equipment to verify unit
operation.
manual output test. See
The ZN510 controller includes a
manual output test function. Use this
feature to manually exercise the
outputs in a defined sequence. The
purpose of the test sequence, is to
verify output and end device
operation. Use the manual output
test to:
Troubleshooting section for Green
LED and Testing Heat Pump
Configurations on page 21 & 22.
The test sequence resets unit
diagnostics and attempts to restore
normal unit operation prior to
testing the outputs. If the diagnostics
remains after a reset, the status LED
indicates the diagnostic condition is
still present and has affected the
z Verify output wiring and
operation without using Trane’s
service tool, Rover.
Analog Outputs
ZN510 does not use analog outputs.
Binary Inputs
The ZN510 controller has three
available binary inputs (BI). These
inputs are factory-configured for
the following functions:
J2-1
Low Temperature
Detection (Circuit 2)
J2-2
z BI 1= Low temperature
detection (freezestat) (Circuit 2).
z BI 2 = Condensate overflow.
J2-3
Condensate Overflow
J2-4
z BI 3 = Occupancy or generic
binary input.
Each binary input may be
configured as not used depending
on options selected. BI 3 is
J2-5
configured as a normally open
occupancy input, but may be field
modified for generic binary input
which is only supported by a build-
ing automation system.
Field Wired
Occupancy Input
J2-6
Figure 6: Binary inputs.
Note:
The diagnostic functions related to
binary inputs such as low tempera-
ture detection and condensate
overflow are fixed sequences.
Table 2: Binary input configurations
Configuratio
n
Contact
Closure
Contact
Open
Binary Input
Description
Each binary input associates an
input signal of 0 VAC with open
contacts and 24 VAC with closed
contacts. See Figure 6 for typical
binary input configurations for the
heat pump.
Low Temperature
Detection (Cir 2)
Normally
closed
BI 1
Normal
Normal
Diagnostic
Diagnostic
Normally
closed
BI 2
Condensate Overflow
Occupancy
Generic
Normally open Unoccupied
Normally open Normal
Occupied
Normal
BI 3
Note:
See Page 10 for specific information concerning BI 1, BI 2 and BI 3.
9
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Unit Operation
Low Temperature Detection
The low temperature detection
diagnostic protects the heat
temperature condition exists for that
circuit.
outdoor air damper also operates
normally.
exchanger by using an analog
leaving water temperature sensor to
protect refrigerant circuit 1 and a
binary low temperature detection
device to protect refrigerant circuit
2. Each individual refrigerant circuit
is disabled when the low
For two compressor units, the
controller responds to low
All unit operation is disabled when
the heat pump shuts down both
circuits, due to low temperature
conditions. See Table 3 for more
information.
temperature detection by allowing
the fan to operate, while disabling
the compressor for the faulty circuit.
The compressor for the normal
circuit continues to operate. The
Table 3: ZN510 response to low temperature detection diagnostic
Fan
Operation
Damper
Operation
Description
Compressor Operation
Low Temperature Detection
(Circuit 1)
Circuit 1-Disabled
Circuit 2-Normal Operation operation
Normal
Enabled
Low Temperature Detection
(Circuit 2)
Circuit 1-Normal Operation Normal
Enabled
Disabled
Circuit 2-Disabled
operation
Closed
Low Temperature Detection
(Circuits 1 and 2)
Circuit 1-Disabled
Circuit 2-Disabled
Note:
z The low temperature detection device automatically resets when the heat exchanger temperature returns to
normal. However, you must manually reset the low temperature detection diagnostic to clear the diagnostic and
restart the unit. Refer to page 28 on how to reset a unit.
z If BOP 6 is configured as a generic binary output, the state of the output is not affected by the low temperature
detection diagnostic or by other diagnostics.
Condensate Overflow
Note:
system), the occupancy binary input
determines the unit’s occupancy
based on the hardwired signal.
Typically, the signal is a dry set of
binary contacts which is either
connected to a switch or timeclock
contacts.
A condensate overflow switch
detects the condensate condition.
The condensate overflow switch is a
normally closed device. This switch
is physically connected to the binary
input 2 (BI 2). When the
condensation reaches the trip point,
the binary input detects the
diagnostic condition. A condensate
overflow signal generates a
diagnostic which disables the fan,
disables all compressors, and closes
the 2-position outdoor air damper
(when present). The condensate
overflow diagnostic does not affect
the generic binary output (when
present).
The condensate overflow switch,
located in the condensate pan, auto-
matically resets when the conden-
sation returns to normal levels.
However, you must manually reset
the controller’s condensate over-
flow diagnostic to clear the diagnos-
tic and restart the unit. Refer to page
28 on how to reset a unit.
When a hardwired occupancy signal
is open, the unit switches to
occupied mode (if the occupancy
input is configured as normally
open). When a hardwired
occupancy signal is closed, the
controller switches to Unoccupied
mode.
Occupancy
ZN510 uses the occupancy binary
input for two occupancy-related
functions. For standalone
controllers (any unit not receiving a
communicated occupancy request,
typically from a building automation
10
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Unit Operation
In Occupied mode, the controller
operates according to the occupied
setpoints. In Occupied Standby
Mode, the unit controller operates
according to the Occupied Standby
setpoints. When the controller
receives a communicated
operates according to the
unoccupied setpoints regardless of
the state of the hardwired
occupancy input.
controller defaults to occupied
mode because the occupancy binary
input (if present) typically is
configured as normally open
without an occupancy device
connected.
If neither the binary input nor the
communicated input is used to
select the occupancy mode, the
unoccupied request, the controller
Table 4: Normally open hardwired input configuration (BI 3)
Description
Communicated Request
NA
Hardwired State
Result
Occupied
Standalone
Standalone
Open = Occupied
NA
Closed = Unoccupied
Open = Occupied
Unoccupied
Communicating
Communicating
Communicating
Communicating
Communicating
Communicating
Occupied
Occupied
Unoccupied
Occupied Standby
Occupied
Open = Occupied
Unoccupied
Open = Occupied
Occupied Standby
Occupied Standby
Unoccupied
Closed = Occupied Standby
Closed = Occupied Standby
Closed = Occupied Standby
Unoccupied
Occupied Standby
Occupied Standby
Note:
If configured for normally closed, all states are opposite of Table 4.
Generic Binary Input
compressor contactor from
energizing keeping the compressor
from running. The controller
automatically detects the fault
condition by measuring the
compressor triac output signal.
unit operation. See Figure 7 for high
and low pressure switch.
Building automation systems can
monitor the status of the generic
binary input. This input does not
affect controller operation.
When the refrigerant circuit returns
to normal, the HPC and the LPC
switches automatically reset. The
high or low pressure cutout
diagnostic may need to be manually
reset to clear the diagnostic and
enable compressor operation for the
fault circuit.
High and Low Pressure
Switches
By default, when the HPC or LPC
switches detect a high or low
pressure condition in the refrigerant
circuit, the special input detects the
diagnostic and disables all
compressor operation for that
circuit. The unit fan continues to
operate, if only one circuit is
disabled in a two compressor unit.
When the HPC/LPC diagnostic is
present on both circuits, the ZN510
shuts off the unit fan and disables
The high and low pressure cutout
switches are wired in series with the
compressor contactor in the unit.
The ZN510 controller detects the
state of each switch circuit by
monitoring the controller’s
compressor triac outputs. If either
the high pressure switch (HPC) or
the low pressure switch (LPC) switch
opens, a fault condition occurs. This
open circuit prevents the
11
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Unit Operation
24 VAC
Compr 2
Compr 1
LPC
HPC
Binary Outputs
Figure 7: High and low pressure switch
Note:
The ZN510 controller includes an automatic diag-
nostic reset function that allows the controller to
automatically recover after a high or low pres-
sure cutout diagnostic. After 30 minutes the con-
troller will reset the diagnostics. Most
diagnostics occur due to intermittent water tem-
perature or flow problem. The “smart reset” may
eliminate many service calls.
1
2
3
4
5
6
7
Analog Inputs
The ZN510 controller has five
available analog inputs (AI). These
inputs are factory-configured for the
following functions:
z Zone = Space temperature.
z Set = Local setpoint.
J3-4
J3-3
Discharge Air
Sensor
z Fan = Fan mode input.
z AI 1 = Leaving water tem-
perature (Circuit 1).
z AI 2 = Discharge air tem-
J3-2
J3-1
perature.
Leaving Water
Sensor (Circuit)
Zone Sensor
See Figure 8 for analog inputs.
Figure 8: Analog inputs.
12
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Unit Operation
Space Temperature
ZN510 controls the space
temperature according to the active
space temperature, the active
heating/cooling setpoint, and the
space temperature control
pressed, the zone sensor sends a
signal to the controller. This signal is
then interpreted as a timed override
cancel which places the unit into
unoccupied.
space temperature, the active
setpoint, and the proportional/
integral control algorithm,
regardless of the presence of a
hardwired or communicated
setpoint.
algorithm. The ZN510 controller
receives the space temperature
from either a wired zone sensor or
as a communicated value. When
neither a zone sensor nor
communicatedspacetemperatureis
present, the ZN510 controller
generates a space temperature
failure diagnostic.
Local Setpoint
Once a valid setpoint is established
(through the hardwired input or
through communication) and when
neither a local setpoint or
communicated setpoint is present,
the controller generates a setpoint
failure diagnostic.
The local setpoint analog input is
designed as the local (hardwired)
setpoint input. This input cannot be
used for any other function. The
local input is a resistance input
intended for use with Trane zone
sensors.
When a setpoint failure diagnostic
occurs, the controller operates using
the default heating and cooling
setpoints. These setpoints are
factory-configured, but may be
changed using the Trane service
tool, Rover.
If neither a hardwired nor
communicated setpoint is present,
the controller uses the stored default
setpoints:
Note:
The ZN510 controller cannot oper-
ate without a valid space tempera-
ture value (either hardwired or
communicated).
z Occupied setpoints:
In the occupied mode, the unit
attempts to maintain the space
temperature at the active
occupied heating or cooling
setpoint based on the measured
space temperature, the active
setpoint, and the proportional/
integral control algorithm.
The space temperature input can
communicate timed override ON or
CANCEL requests to the ZN510
controller. If the ON button is
temporarily pressed, the zone
sensor sends a signal to the
controller. This signal is then
interpreted as a timer override
request which places the unit into
occupied.
The ZN510 controller uses the
following validation sequence for
the setpoints:
1. Check for a communicated
setpoint. If present, validate this
setpoint.
z Occupied standby setpoints:
In occupied standby mode, the
controller uses the occupied
standby cooling and heating
setpoints. Because the occupied
standby setpoints typically
cover a wider range than the
occupied setpoints, the ZN510
controller reduces the demand
for heating and cooling the
space. Also, the outdoor air
damper is normally closed
during occupied standby mode
to further reduce the heating
and cooling demands.
2. Check for a hardwired setpoint
and validate the setpoint.
3. Use the default setpoint and
The controller uses the timed
override request (while the zone is
unoccupied) as a request to switch
to the Occupied Bypass mode
(occupied bypass). This Occupied
Bypass mode lasts for the duration
of the occupied bypass time,
typically 120 minutes.
validate this setpoint.
Fan Mode Input
The fan mode analog input (Fan) is
designed to operate as the fan mode
switch input. This input cannot be
used for any other function. The fan
switch on a Trane zone sensor
generates the fan mode signal.
or
The controller’s Occupancy mode is
determined from either a system
level controller or another peer
controller.
The ZN510 controller detects the
unique resistance corresponding to
each position of the fan switch. By
measuring the resistance, the
controller determines the requested
fan mode.
z Unoccupied setpoints:
In unoccupied mode, the unit
attempts to maintain the space
temperature at the stored unoc-
cupied heating or cooling
The CANCEL button cancels the timed
override request and returned the
unit to unoccupied mode. If the
CANCEL button is temporarily
setpoint based on the measured
13
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Unit Operation
Leaving Water Temperature
ZN510 uses analog input 1 (AI 1) as
the leaving water temperature input
for use with a thermistor. This input
(AI 1) is automatically assigned as a
leaving water temperature input. As
explained in the binary input
section, the leaving water
temperature input protects the heat
exchanger (circuit 1) from low
temperatures. The second heat
exchanger, present in units with two
compressors is protected with a
binary low temperature detection
device. Based on the application of
the unit, circuit operation is
See the Diagnostics section on page
28 for information about the
automatic diagnostic reset function.
Possible
Fan Modes
Heat Pump
(1-speed)
Filter Maintenance Timer
The controller’s filter maintenance
timer is based on the unit fan’s
cumulative run hours. The controller
compares the fan run time against
an adjustable fan run hours limit
(maintenance required setpoint
time, stored in the controller) and
recommends unit maintenance (i.e.
changing the filter).
OFF
Fan Off
Continuous: (Field
Modified)
z In occupied mode, the
fan runs continuously.
In unoccupied mode,
the fan cycles OFF
AUTO
when no heating or
cooling is required.
Cycling: (Factory Default)
Use Rover or BAS system to edit the
maintenance required setpoint time.
Once the setpoint limit is exceeded
the controller generates a filter
maintenance timer diagnostic.
When the maintenance required
setpoint time is zero, the controller
disables the diagnostic feature.
z The fan cycles ON and
OFF with compressor
operation.
AUTO
terminated when the leaving water
temperature falls below 35 F or
20 F. This is set when the unit is
ordered.
The ZN510 controller receives the
fan mode from either a wired zone
sensor or as a communicated valve.
When neither a zone sensor nor
communicated fan mode are
The ZN510 controller compares the
measured leaving water
temperature to the leaving water
temperature low limit value to
determine a fault condition. When
the measured leaving water
temperature is less than the leaving
water temperature low limit, the
controller generates a Low Temp
Detect diagnostic. If the Leaving
Water Temp Sensor fails to open or
close the controller generates a
Leaving Water Temp Failure
diagnostic. This disables unit
operation.
Discharge Air Temperature
Analog input 2 (AI 2) is used as the
discharge air temperature input for
use with a 10,000 ohm thermistor.
Typical factory placement of the
thermistor is at the discharge area of
the unit. The discharge air
temperature sensor does not affect
unit operation. The measured
temperature is for information only
to be read by the building
present, the ZN510 controller will
default unit operation to AUTO.
Note:
z A building automation system
can also generate a fan mode
request and communicate this
request to the controller.
z If the ZN510 controller does not
receive a hardwired or commu-
nicated request for the fan
mode, the unit recognizes the
fan input as AUTO and the fan
operates according to the
automation system or for
troubleshooting unit operation with
Rover.
Note:
A low temperature detection failure
diagnostic for compressor 1 may
require you to manually reset the
unit to restore compressor opera-
tion.
Once a valid discharge air
default configuration.
temperature signal has been
established by the thermistor or
communicated and the value is no
longer present, the controller
generates a discharge air
temperature failure diagnostic. This
will not disable unit operation. If the
sensor returns with a valid
temperature, the diagnostic
automatically clears
Fan Off Delay
When the heating output is
controlled off, the ZN510
automatically runs the fan ON for an
additional 30 seconds to give the fan
time to blow off any residual heat.
Similarly, the ZN510 controller uses
a binary low temperature detection
device (fixed low limit trip point) to
lock-out circuit 2 when a fault condi-
tion is detected.
14
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Zone Sensor
Zone Sensor
The ZN510 controller accepts the
following zone sensor inputs:
values exist, the controller ignores
the hardwired space temperature
input and uses the communicated
value.
(when present) is exposed on the
zone sensor’s front cover.
When the hardwired setpoint
adjustment is used to determine the
setpoints, all unit setpoints are
calculated based on the hardwired
setpoint values, the configured
setpoints, and the active mode of
the controller.
z Space temperature mea-
surement.
Internal and External Setpoint
Adjustment
Zone sensors with an internal or
z Local setpoint (internal or
external on the zone sensor).
external setpoint adjustment
provide the ZN510 controller with a
local setpoint (50 to 85 F or 10 to 29.4
C). The internal setpoint adjustment
is concealed under the zone sensor’s
cover. To reveal the adjustable
setpoint wheel, remove the zone
sensor cover. The external setpoint
z Fan switch. (Optional)
z Timed override (ON and CANCEL).
z Communication Jack.
Setpoint Operation
The controller has three methods of
heating and cooling setpoints
operation. See Table 5 for the
methods of setpoint operation.
If both hardwired and
communicated space temperature
Table 5: Methods of setpoint operation.
Method
Situation used
Zone Sensor
(with an adjustable hardwired
setpoint)
A hardwired, adjustable setpoint is connected to the controller. Local setpoints are
enabled in the unit configuration. No communicated setpoint is present.
A setpoint is communicated to the unit controller (typically from a building automation
system or a peer controller). If both a hardwired setpoint and a communicated setpoint
exist, the controller uses the communicated value. The configuration feature for enabling
or disabling the local setpoint does not affect the setpoint handling when communicated
setpoints are used. The communicated setpoint always takes priority over the hardwired
setpoint, even when the local setpoint is enabled.
Communicated source
Stored default setpoints
The controller uses the locally stored default heating and cooling setpoints when neither
a local hardwired setpoint or communicated setpoint is present. When a building
automation system is present, the controller uses the default setpoints when no setpoint
is communicated to the controller and no hardwired setpoint exists. The controller uses
stored default setpoints when only a local setpoint exists, but the local setpoint is
disabled in the configuration of the controller. The controller always uses the stored
default (unoccupied) setpoints in unoccupied mode.
15
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Zone Sensor
Zone Sensor Features
Fan Switch (Optional)
during unoccupied mode places the
controller in occupied bypass mode
for 120 minutes. You can adjust the
number of minutes in the unit
controller configuration using
Trane’s service tool, Rover. The
controller remains in occupied
standby mode until the override
timer expires or until the CANCEL
button is pressed.
controller). By accessing the
communication jack via Rover,
entrance to all controllers on the link
may be gained.
The zone sensor fan switch provides
the controller with an occupied (and
occupied standby) fan request signal
of OFF or AUTO. If the fan control
request is communicated to the
controller, the controller ignores the
hardwired fan switch input and uses
the communicated value. The zone
sensor fan switch signal can be
enabled or disabled through
configuration in the ZN510
Communication Jack
Use the RJ-11 communication jack
as the connection point from Rover
to the communication link (when the
communication jack is wired to the
communication link at the
controller.
ON or CANCEL Buttons
Momentarily pressing the ON button
Table 6: Zone Sensor Options
Part Number:
X13510628010
Description:
ZONE
RT1
10K OHM @
25 °C ± 2°C
1
SIGNAL (COMMON)
2
3
4
5
VR1
R7 1K
200
CSP
z Space temperature (0.2 C
ADJUSTABLE
SETPOINT
resolution).
COMM HIGH (+ )
z Internal setpoint.
z Communication jack.
z Vertical case with Trane logo
COMM LOW (-)
COMMUNICATIONS
JACK
MJ1
ZONE
RT1
10K OHM @
25 °C ± 2°C
1
2
3
4
Part Number:
X13510606010
Description:
SIGNAL (COMMON)
VR1
R7 1K
200
CSP
ADJUSTABLE
SETPOINT
z Space temperature (0.2 C
COMM HIGH (+ )
resolution).
z External setpoint.
z Communication jack.
z Vertical case with Trane logo
COMM LOW (-)
5
COMMUNICATIONS
JACK
MJ1
16
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Zone Sensor Specifications
Part Number:
X13510606020
Description:
z Space temperature (0.2 C
resolution).
z External setpoint.
z ON and CANCEL buttons.
z Communication jack.
z Vertical case with Trane
logo.
Part Number:
X13510635010
Description:
z Space temperature (0.2 C
resolution).
z External setpoint.
ON
z Fan Switch (OFF and
AUTO).
z ON and CANCEL buttons.
z Communication jack.
z Vertical case with Trane
logo.
17
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Heating or
Cooling Control
Mode Operation
Heating or Cooling
Operation
For both single and dual compressor
operation, the ZN510 controller
cycles the compressor(s) on and off
to meet heating or cooling zone
demands. The controller uses the
unit capacity and pulse width
controlling only the first
modulation (PWM) logic along with
minimum on/off timers to determine
the operation for compressor 1.
compressor, the controller runs
compressor 1 continuously and
controls compressor 2 according to
PWM logic along with the minimum
on/off timers. See Table 6 for heat
pump heating or cooling operation.
With a dual compressor unit, if the
desired conditions are not met by
Table 7: Heat pump heating or cooling operation*
Capacity
Unit
Between
0 and 50%
Between
100%
0%
50 and 100%
Compressor output is controlled according to pulse width
modulation (PWM) logic between 0 and 100%. The
controller calculates the compressor on/off times based
on PWM logic and heating/cooling capacities. The
compressor is controlled on for longer periods as the
capacity increases and shorter periods as the capacity
decreases.
Compressor OFF
continuously.
Compressor ON
continuously.
Single compressor
Both compressors
OFF continuously.
#1: ON PWM.
#2: OFF continuously.
#1: ON continuously.
#2: ON PWM.
Both compressors ON
continuously.
Dual (Two) compressors
*Note: No diagnostics present.
Certain heat pump configurations
may use one or two compressors for
cooling control. Heat pumps use
reversing valve control to switch
between heating and cooling. The
controller supports cooling only
configurations and heat pump
configurations.
simultaneously de-energizing the
reversing valve. The reversing valve
only changes state when the
controller uses the compressor
stages for cooling.
controller turns on compressor 1.
Compressor Minimum
ON/OFF Timers
When a power failure occurs, the
reversing valve output defaults to
the heating (de-energized) state. To
reduce noise due to refrigeration
migration after compressor
shutdown, the controller does not
immediately operate the reversing
valve. The reversing valve changes
state only when the compressor
controls on, except when the
z When fan mode = OFF, Com-
pressor minimum ON timers are
ignored.
For heat pump configurations, the
unit’s reversing valve is energized in
cooling and de-energized in heating.
For cooling, the reversing valve
output is energized simultaneously
with the compressor (compressor 1
in two compressor applications).
The reversing valve remains
z When fan mode = AUTO, Com-
pressor minimum OFF timers are
observed.
z The diagnostic reset ignores the
compressor timers ON and OFF.
controller is in off mode.
z A communicated compressor
disabled or unoccupied signal
ignores minimum ON times.
energized until the controller turns
on the compressor for heating,
For cooling only configurations, no
reversing valve is present and the
18
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Single and Dual
Compressor
Operation
Other Modes
Occupancy Operation
controller interprets the request and
initiates the occupied setpoint
operation. During a timed override,
the controller applies the occupied
heating and cooling setpoint, but
reports the effective occupancy
mode as occupied bypass mode. In
the occupied bypass mode, a
building automation system can
detect whether the occupancy mode
was overrode.
damper normally is open during the
occupied mode when the controller
turns on the unit fan. The damper is
normally closed during:
Unoccupied operation normally is
associated with evening hours when
the space is vacant. In unoccupied
mode, the controller always uses the
default unoccupied heating and
cooling setpoints stored in the
controller. As the unit goes
unoccupied, the compressors ON
timers are ignored and the
z occupied mode when the fan is
OFF.
z warm up/cool down mode.
z occupied standby mode.
z unoccupied mode.
compressors are disabled.
Morning Warm Up
z certain diagnostic conditions.
When ZN510 controls the space to
unoccupied mode, the occupant
may have the ability to request
timed override through the Trane
zone sensor’s ON button. Based on
the controller or system setup, the
The damper (field installed or for the
console product) remains closed
during morning warm up until the
space temperature is within two
degrees of the effective heating
setpoint. The 2-position outdoor air
ZN510 keeps the 2-position outside
air damper closed on a transition
from unoccupied mode to occupied
mode as part of the morning warm
up sequence.
19
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Data Sharing
Master Controller
ZN510 can send or receive data
(such as setpoint, heat/cool mode,
fan request and space temperature)
to and from other controllers on the
communication link, with or without
a building automation system. This
includes applications where
Master Controller
ON
CANCEL
multiple unit controllers share a
common space temperature sensor,
both for standalone and building
automation applications.
Zone Sensor
Communication Link
The master controller (the unit
controller with the hardwired zone
sensor) in peer-to-peer
communication can send its zone
temperature to one or more slave
controllers which allows the slave
controllers to track each other’s
zone temperature. For these
applications, Rover is used in set up
of the controller.
Slave Controller
Slave Controller
Figure 9: Master/slave setpoint operation for peer-to-peer setup
See Figure 9 for Master/Slave
setpoint operation for peer-to-peer
set up.
Setpoint Operation
Controllers sharing information
peer-to-peer can share a variety of
data, including the heating/cooling
setpoint (communicated from a
master to a slave).
Note:
z Heating/cooling mode.
z Occupancy.
Each controller derives it’s effective
setpoint and default setpoints
(including deadbands between set-
points) from the setpoint input
(hardwired or communicated). To
make sure the peer-to-peer setpoint
application results in identical set-
points for each communicating con-
troller, each controller must have
exactly the same default setpoints.
z Fan status.
The standalone master controller
derives its setpoint from either the
local hardwired setpoint input or
from its default setpoints. Peer-to-
peer applications often require the
use of one hardwired setpoint to be
shared across two or more
controllers. This can be achieved by
wiring the adjustable setpoint
(typically included as a part of the
Trane zone sensor module) to the
controller defined as the master.
Trane’s service tool, Rover may be
used to set up the master and one or
more slaves to share that setpoint.
For this application, each
z Unit control algorithm capacity.
This information is communicated
from the master to the slave to
ensure similar unit operation.
Use Rover, Trane’s service tool, to
set up peer-to-peer applications.
Simplified Peer-to-Peer (Master/
Slave) Setup
Refer to the Rover product literature
for more information on setting up
applications.
To simplify setting up master/slave
applications, the controller provides
information that groups all
necessary shared data into one
communication variable. This
master/slave variable includes the
following information:
communicating controller uses the
same setpoint.
z Space temperature.
z Setpoint.
20
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Configuration
Configurable Parameters
information, such as the default
analog inputs, the default binary
inputs, and the default binary output
configurations. See Table 7 for
default configurations for heat
pumps.
Rover, Trane’s service tool, uses the
unit type “heat pump” to determine
and download unit configuration
Table 8: Heat pump heating or cooling operation.
Unit Type
Heat pump
Cooling Source
Heating Source
Compressors
Compressor
Compressor (none for cooling only units)
1 (2 for 2-compressor units)
BOP 1: Fan on (normally open)
BOP 2: Reversing valve (normally open)*
BOP 3: Not used
BOP 4: Compressor 1 (normally open)
BOP 5: Compressor 2 (normally open)**
BOP 6: Outdoor Air Damper (normally open)***
Binary Outputs
BI 1: Low temperature detection, circuit 2 (normally closed)*
**
BI 2: Condensate overflow (normally closed)†
BI 3: Occupancy (normally open)
Binary Inputs
Analog Inputs
Zone: Space temperature (0.0 F calibration)
Set: Setpoint (0.0 F calibration)
Fan: Fan mode
AI 1: Leaving water temperature
AI 2: Discharge air temperature
Fan operation (heating): Cycling
Fan operation (cooling): Cycling
Fan speed default (heating): On/high
Fan speed default (cooling): On/high
Fan switch (hardwired): Enabled
Fan
Unoccupied cooling setpoint: 85 F
Occupied standby cooling: 78 F
Occupied cooling setpoint: 74 F
Occupied heating setpoint: 71 F
Occupied standby heating: 67 F
Unoccupied heating setpoint: 60 F
Cooling setpoint high limit: 115 F
Cooling setpoint low limit: 40 F
Heating setpoint high limit: 115 F
Heating setpoint low limit: 40 F
Thumbwheel set point: Enabled
The heating and cooling setpoint
high and low limits only apply to the
occupied and occupied standby
setpoints. These limits never apply
to the unoccupied setpoints.
Setpoints
The occupied bypass time is used for timed
override applications. The timed override
timer is maintained in the unit controller.
When the timed override is applicable, the
controller reports “Occupied Bypass” as its
effective occupancy mode.
Occupied Bypass
Timer
120 minutes
Leaving Water
Temperature
Low Limit
Unit specific (20 F ground source or 35 F standard)
Unit specific (maximum of 30 characters)
Location Identifier
The leaving water temperature low
limit is used for freeze protection of
circuit 1 on heat pumps. Circuit 2 is
protected by a binary low
temperature detection device
(freezestat) with a fixed trip point.
* BOP 2, BI1: Not used on cooling only units.
** BOP 5: Not used on signal compressor unit.
*** Configured but not required.
† Optional model number dependent
21
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Troubleshooting
Red Service LED
Table 9: Red LED activity
Red LED Activity
Description
LED off continuously when power is applied to the
controller.
Normal operation.
LED on continuously, even when power is applied to Someone is pressing the service button or the controller has
the controller.
failed.
Use Rover, Trane’s service tool, to restore the unit to normal
operation or unconfigured.
LED flashes once every second.
!Warning! Service Button
The black Service button on the ZN510 board allows the user to send a service pin message, which allows
efficient identification of the unit's location. However, if the Service button is held for more than 10
seconds, the ZN510 will shut down the software application and disable the unit's operation. The only
method to restore the unit is through the use of Rover service tool. We strongly suggest that this function
only be exercised under the strict direction of factory service personnel.
Green Status LED
The green LED normally indicates
Table 10: Green LED activity
whether the controller is powered
on (24 VAC).
Green LED Activity
Description
LED on continuously.
Power on (normal operation).
Manual output test mode (2-second hold), No
diagnostics present.
LED blinks (one blink).
LED blinks (two blinks).
Manual output test mode (2-second hold),
One or more diagnostics are present.
“Wink” mode.
This feature allows the identification of a
controller. By sending a request from a device,
such as Rover, Trane’s service tool or ZN510
Loop Controller, a request to the controller
can be made to “wink” a notification that the
controller received the signal. When the zone
sensor ON button is held for 10 seconds
“Wink” mode is sent from Comfort Link
Controller.
LED blinks (1/4 second on,
1/4 second off for 10 seconds.
z Power off.
z Abnormal condition.
z Test button is pressed.
LED off.
Yellow Service LED
Table 11: Yellow LED activity
Yellow LED Activity
Description
The controller is not detecting any communication.
(Normal for standalone applications).
LED off continuously.
The controller detects communication. (normal for
communicating applications, including data sharing).
LED blinks.
LED on continuously.
Abnormal condition.
22
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Troubleshooting
Manual Output Testing the Heat
Pump Configurations
The procedure for testing heat pump
for at least three seconds to
start the test mode.
3. Press the Test button several
more times (no more than once
per second) to advance through
the test sequence.
2. The test sequence resets
diagnostics and turns off all
outputs.
configurations is:
1. Press and hold the Test button
Table 12: Test sequence
Fan
BOP 1
Reversing Valve
BOP 2
Compr 1 Compr 2
BOP 4 BOP 5
Damper
BOP 6
Step
1. Off
Off
Off
Off
Off Off
Closed
2. Fan on (At the beginning of step 2, the
controller attempts to clear all diagnostics).
On
Off
Off
Closed
3. Reversing Valve
4. Cool 1
On
On
On
On
On
On
Off
On
On
Off
Off
On
Closed
Closed
Closed
5. Cool 2
6. Compressor(s) off
This stage helps avoid compressor cooling
and heating in sequential steps by turning the On
compressors off prior to changing the
reversing valve state.
Off
Off
Off
Closed
7. Heat 1
On
On
On
Off
Off
Off
On
On
Off
Off
On
Off
Closed
Closed
Open
8. Heat 2
9. Outdoor air damper
10. Exit
After the outdoor air damper step, the test
sequence performs the exit step. This
initiates a reset and attempts to return the
controller to normal operation.
Testing the Heat Pump
Configurations
The outputs are not subject to
minimum times during the test
sequence. However, the test
sequence only permits one step per
second which limits output time.
the same as two compressor units.
For single compressor units, the
cool 2 and heat 2 steps control the
appropriate binary outputs, but do
not affect unit operation.
Pump Operation for
Systems with ZN510
Loop Controller
During Unoccupied, the pumps will
be OFF but should be energized to
test compressor operation. The user
must override the pumps either at
the ZN510 Loop Controller or by
pushing the ON button of the zone
sensor. This will send the units to an
occupied bypass, which will turn the
pumps on prior to operating
manual output test.
Reversing valve and damper
outputs cycle independent of
configuration.
All outputs are exercised regardless
what timer they are or are not
configured for. For example, single
compressor heat pumps function
23
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Troubleshooting
Questionable Unit
Operation
Table 13: Fan output does not energize
Probable Cause
Explanation
After power up, the controller always observes a random start from 0 to 25
seconds. The controller remains off until the random start time expires.
Random start observed.
Power up control wait.
When power up control wait is enabled (non-zero time), the controller remains
off until one of two conditions occurs:
z The controller exits power up control wait once it receives commu-
nicated information.
z The controller exits power up control wait once the power up control
wait time expires.
When configured to cycle with capacity, normally the unit fan cycles off with
heating or cooling. The heating/cooling sources cycle on or off periodically with
the unit fan to provide varying amounts of capacity to the space.
Cycling fan operation.
Unoccupied operation.
Even when the controller is configured for continuous fan operation, the fan
normally cycles with capacity during unoccupied mode. While unoccupied, the
fan cycles on or off with heating/cooling to provide varying amounts of heating
or cooling to the space.
When a local fan mode switch determines the fan operation, the off position
controls the unit fan off.
Fan mode off.
The desired operating mode (such as off, heat and cool) can be communicated to
the controller. When off is communicated to the controller, the unit controls the
fan off. There is no heating or cooling.
Requested mode off.
Diagnostic present.
A specific list of diagnostics affects fan operation. See Diagnostics section on
page 27.
If the controller does not have power, the unit fan does not operate. For the
ZN510 controller to operate normally, it must have an input voltage of 24 VAC.
When the green LED is off continuously, the controller does not have sufficient
power or has failed.
No power to the controller.
Unit configuration.
Manual output test.
Unit wiring.
The controller must be properly configured based on the actual installed end
devices and application.
The controller includes a manual output test sequence that may be used to verify
output operation and associated output wiring. However, based on the current
step in the test sequence, the unit fan may not be on. Refer to the manual output
overrides on page 9.
The wiring between the controller outputs and the fan relays and contacts must
be present and correct for normal fan operation.
24
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Troubleshooting
Questionable Unit
Operation
Table 14: Compressor(s) not running
Probable Cause
Explanation
The controller compressor(s) turn on and off to meet the unit capacity
requirements.
Normal operation.
The desired operating mode (such as off, heat and cool) can be communicated to
the controller. When off is communicated to the controller, the unit shuts off all
unit compressor(s).
Requested mode off.
Numerous communicated requests may disable the compressor, including a
compressor enable input. Depending on the state of the communicated request,
the unit may disable the compressor.
Communicated disable.
Manual output test.
The controller includes a manual output test sequence that may be used to verify
output operation and associated output wiring. However, based on the current
step in the test sequence, the compressor(s) may not be on. Refer to the manual
output overrides on page 9.
A specific list o f diagnostics affects compressor operation, depending whether
the unit is configured as heat pump. For more information, see the Diagnostics
section on page 27.
Diagnostic present.
Unit configuration.
The controller must be properly configured based on the actual installed end
devices and application. When the unit configuration does not match the actual
end device, the compressor may not work correctly.
If the controller does not have power, the compressor does not operate. For the
ZN510 controller to operate normally, a voltage input of 24 VAC must be applied.
When the green LED is off continuously, the controller does not have sufficient
power or has failed.
No power to the controller.
Unit wiring.
The wiring between the controller outputs and the compressor contacts must be
present and correct for normal compressor operation.
Table 15: Outdoor air damper stays open
Probable Cause
Explanation
The controller opens and closes the outdoor air damper based on the controller’s
occupancy mode and fan status. Normally, the outdoor air damper is open
during occupied mode when the fan is running and closed during unoccupied
mode. Refer to the outdoor air damper section on page 8.
Normal operation.
Manual output test.
The controller includes a manual output test sequence that may be used to verify
output operation and associated output wiring. However, based on the current
step in the test sequence, the outdoor air damper may not open. Refer to the
manual output overrides on page 9.
The controller must be properly configured based on the actual installed end
devices and application. When the unit configuration does not match the actual
end device, the outdoor air damper may not work correctly.
Unit configuration.
Unit wiring.
The wiring between the controller outputs and the compressor contacts must be
present and correct for normal damper operation.
25
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Troubleshooting
Questionable Unit
Operation
Table 16: Outdoor air damper stays closed
Probable Cause
Explanation
The controller opens and closes the outdoor air damper based on the controller’s
occupancy mode and fan status. Normally, the outdoor air damper is open
during occupied mode when the fan is running and closed during unoccupied
mode. Refer to the outdoor air damper section on page 8.
Normal operation.
The controller includes both a morning warm-up and cool down sequence to
keep the outdoor air damper closed during the transition from unoccupied to
occupied. This is an attempt to bring the space under control as quickly as
possible.
Warm up and cool down.
Requested mode off.
Manual output test.
The desired operating mode (such as off, heat and cool) can be communicated to
the controller. When off is communicated to the controller, the unit closes the
outside air damper.
The controller includes a manual output test sequence that may be used to verify
output operation and associated output wiring. However, based on the current
step in the test sequence, the outdoor air damper may not be open. Refer to the
manual output overrides on page 9.
A specific list o f diagnostics affects outdoor air damper operation, depending
whether the unit is configured as heat pump. For more information, see the
Diagnostics section on page 27.
Diagnostic present.
Unit configuration.
The controller must be properly configured based on the actual installed end
devices and application. When the unit configuration does not match the actual
end device, the outdoor air damper may not work correctly.
If the controller does not have power, the compressor does not operate. For the
ZN510 controller to operate normally, a voltage input of 24 VAC must be applied.
When the green LED is off continuously, the controller does not have sufficient
power or has failed.
No power to the controller.
Unit wiring.
The wiring between the controller outputs and the outdoor air damper must be
present and correct for normal outdoor air damper operation.
26
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Diagnostics
Table 17: ZN510 controller diagnostics
Diagnostic
Condensate overflow
Fan
Other Outputs
Compressors: Off
Off
Damper: Closed
Compressor 1: Off
Low temp detect - Crt 1
Enabled
Enabled
Off
Compressor 2: See note below.
Damper: See note below.
Compressor 1: See note below.
Compressor 2: Off
Damper: See note below.
Low temp detect - Crt 1
Compressor 1: Off
Compressor 2: Off
Damper: Closed
Low temp detect - Crt 1 and 2
High/low press cutout - Crt 1
High/low press cutout - Crt 2
Compressor 1: Off
Compressor 2: See note below.
Damper: See note below.
Enabled
Enabled
Compressor 1: See note below.
Compressor 2: Off
Damper: See note below.
Compressor 1: Off
Compressor 2: Off
Damper: Closed
High/low press cutout - Crt 1 and 2
Space temperature failure*
Off
Off
Compressor(s): Off
Damper: Closed
Compressor 1: Off
Compressor 2: See note below.
Damper: See note below.
Leaving water temp failure
Enabled
Compressor(s): No action
Damper: No Action
Discharge air temp failure*
Enabled
Enabled
Enabled
Enabled
Disabled
Maintenance required
(example: Filter Status)
Compressor(s): No action
Damper: No Action
Compressor(s): Enabled
Damper: Enabled
Local setpoint failure*
Local fan mode failure*
Invalid unit configuration
Compressor(s): Enabled
Damper: Enabled
Compressor(s): Disabled
Damper: Disabled
High/low pressure cutout and low temperature detection diagnostics for heat pump configurations isolate
each circuit and independently disable compressor operation. For single compressor units, these diagnostics cause
the compressor to shut down, the unit fan to be controlled off, and the outdoor air damper to be closed (when
present).
When BOP 6 is configured as a generic binary output, BOP 6’s state is unaffected by all unit diagnostics.
* Note: Non-latching diagnostics automatically reset when the input is present and valid.
27
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Diagnostics
Translating Multiple
Diagnostics
z High/low pressure cutout,
Rover Service Tool
Circuit 1 and 2
Trane’s service tool, Rover, can reset
diagnostics in the ZN510 controller.
For complete information about
Rover, refer to the Rover product
literature.
The controller senses and records
each diagnostic independently of
the diagnostics. It is possible to have
multiple diagnostics present
simultaneously. The diagnostics are
reported in the order they occur.
When one or more of these special
diagnostics occurs, the controller
responds to the diagnostic as
defined in the table 17 on page 27.
After the controller detects the first
special diagnostic (listed on page
27), the unit waits 30 minutes before
invoking the automatic diagnostic
reset function. The automatic
diagnostic reset function clears all
special diagnostics and attempts to
restore the controller to normal
operation. The controller resumes
normal operation until another
diagnostic occurs.
Alarm Reset
Any device that can communicate
alarm reset information can reset
diagnostics in the ZN510 controller.
Resetting Diagnostics
1. Automatically by the controller.
2. By initiating a manual output
ZN510 Controller Replacement
1. Disconnect power or disable
the circuit breaker to unit.
test at the controller.
3. By cycling power to the
controller.
2. Remove bad or questionable
ZN510 Controller.
4. Through a building automation
system such as ZN510 Loop
Controller.
3. Install controller in the unit with
the heatsink placement at the
top of the control box. (See
page 32).
If a special diagnostic occurs within
24 hours after an automatic
diagnostic reset, the diagnostic
must be manually reset.
5. Through Rover, Trane’s service
tool.
4. Connect the power to the ZN510
6. Through any communicating
device with the ability to access
the controller’s alarm reset
input.
Cycling Power
ONLY. (TB1-1 & TB1-2 on ZN510)
When the 24 VAC power to the
controller has been turned off, the
unit cycles through a power up
sequence. By default, the controller
attempts to reset all diagnostics at
power up. Diagnostics present at
power up and those that occur after
power up are handled according to
the table on page 27.
5. Connect Rover and properly
configure the controller, unless
a previously configured board
is purchased.
Automatic Diagnostic Reset
The ZN510 controller includes an
automatic diagnostic reset function.
This function attempts to
automatically recover a unit when
the following diagnostics occur:
z Low temperature detection,
Circuit 1
6. Power down.
7. Connect the remaining input
and output wiring to the
controller.
Building Automation System
(CLC)
8. Reapply power.
z Low temperature detection,
Some building automation systems
can reset diagnostics in the ZN510
controller. The ZN510 Loop
Controller can reset diagnostics in
the ZN510 Controller. For complete
information, refer to the building
automation system product
literature.
9. Complete sequence 7 and 8
above in the installation section
of this manual.
Circuit 2
z Low temperature detection,
Circuit 1 and 2
10. Refer to BAS manual for
instructions on how to install
the new ZN510 into BAS
system.
z High/low pressure cutout,
Circuit 1
z High/low pressure cutout,
Circuit 2
28
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Wiring Diagram
29
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Wiring Diagram
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Hardware
Specifications
Specifications
Storage Environment
-40 to 185 F (-40 to 85 C)
5 to 95% non-condensing
Power Requirements
18 to 32 VAC (24 VAC nominal)
50 or 60 Hz
(EFT), IEC 1000-4-5 (Surge), FCC Part
15, Class A.
Board Dimensions
Input/Output Summary
z Three binary inputs.
Height:
Width:
Depth:
4” (102 mm)
z Six binary outputs only five are
5-1/2” (140 mm)
2-1/4” (57mm)
300 mA
used.
z Five analog inputs.
Agency Listings
z Timed override ON and CANCEL.
z Comm5 communication.
UL and CUL 916 Energy
Management System
Agency Compliance
Operating Environment
32 to 140 F (0 to 60 C)
5 to 95% non-condensing
IEC 1000-4-2 (ESD), IEC 1000-4-4
Heat sink is mounted to the top
of the control box
4”
5 1/2”
Figure 10: ZN510 Circuit Board
31
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Hardware
Specifications
Table 18: Binary Inputs
Description
Terminals
Function
Binary Input 1
J2-1
J2-2
J2-3
J2-4
J2-5
J2-6
24 VAC
Input
Binary Input 2
Binary Input 3
24 VAC
Input
24 VAC
Input
Table 19: Binary Outputs
Output
Description
Terminals
Load Energized
Rating
Load De-energized
Binary Output 1
Binary Output 2
Binary Output 3
Binary Output 4
Binary Output 5
Binary Output 6
J1-1
J1-2
J1-4
J1-5
J1-6
J1-7
12 VA
1 VAC RMS (typical)
1 VAC RMS (typical)
24 VAC RMS (typical)
24 VAC RMS (typical)
12 VA
NOT USED
12 VA
1 VAC RMS (typical)
1 VAC RMS (typical)
1 VAC RMS (typical)
24 VAC RMS (typical)
24 VAC RMS (typical)
24 VAC RMS (typical)
12 VA
12 VA
Table 20: Analog Inputs
Description Terminals
Zone
Function
Range
TB3-1
TB3-2
TB3-3
TB3-4
Zone temperature input
Analog ground
5 to 122 F (-15 to 50 C)
Ground
Set
NA
Setpoint input
40 to 115 F (4.4 to 46.1 C)
Fan
Fan switch input
OFF = 4821 to 4919 Ohms
AUTO = 2297 to 2342 Ohms
Ground
TB3-6
J3-1
Analog ground
NA
Analog Input 1
Leaving water
temperature
-40 to 212 F (-40 to 100 C)
J3-2
J3-3
J3-4
Analog ground
NA
Analog Input 2
Discharge air temperature -40 to 212 F (-40 to 100 C)
Analog ground NA
32
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