tr-10 trane rtu system enhancer installation instructions...tr-10 trane® rtu system enhancer...

TR-10 Trane® RTU System Enhancer Installation Instructions

Description

Novar’s TR-10 Trane RTU System Enhancer is an intelligent distributed control modulethat is part of Novar’s Logic One® Building Management System. The module provides

direct digital control of unitary, packaged Trane rooftop heating, ventilating, andair-conditioning (HVAC) units. Itmounts in the control panel of the rooftop unit and controls the fan, cooling,heating, and damper. The TR-10contains an RS-485 MODBUS®

communications link to the TraneCommunications Interface (TCI). Thisenables it to receive diagnostic data fromthe Trane control system and display it on Novar’s front-end software, ESS32 andiScope®. Via the communications link, itcan also reset compressor faults.

In addition to the typical connections for space and discharge-air temperatures, the TR-10 provides a connection for a third temperature sensor. This sensor can be used for avariety of control modes, including a fall-back mode of operation that allows a return-airsensor to control the unit if the signal is lost from the space temperature sensor.

This document provides instructions for field mounting the TR-10 inside the Tranerooftop unit with or without the optional hinged mounting brackets, wiring the module,and setting the module’s address.

Disclaimer

Novar customers who choose to make use of the TR-10’s ability to read diagnosticmessages from the Trane equipment must accept the following potential limitations ofthis interface.

The ability of the TR-10 to read the Trane diagnostic messages requires that the TraneUnitary Control Processor (UCP) module uses Comm 4 protocol. Not all Trane UCPsuse this protocol; therefore, Novar cannot guarantee 100% compatibility. In general, thefollowing guidelines can be applied:

§ Newer Voyager™ Rooftop Units that contain the ReliaTel™ controller appear to usethe compatible protocol.

§ Voyager Rooftop Units that are less than 8 years old that contain the UCP and TCI(Trane Communications Interfaces) appear to use the compatible protocol. On olderUCPs, if the last three digits before the dash in the software revision number (locatedon one of the large black relays on the bottom of the board or on the microprocessor)are 500 or greater, it should be compatible with Comm 4 protocol.

Sample of compatible UCP Software Revision Number: X-13650500-02

REV. C 11/30/07 569063100

For units that are not compatible with the selected protocol, the TR-10 offers a softwareselection to turn off the communications interface, which prevents error messages andalarms from occurring. The TR-10 will continue to offer all other standard ETM-stylecontrol features on which Novar’s customers have come to rely.

Novar cannot be held responsible for resolving protocol issues with incompatible units.

Specifications

Agency Approvals

Listed device: CUL/UL E90949Standards used: UL Energy Management Equipment UL 916 and

CSA Signal Equipment C22.2, No. 205-M1983

Power Requirements

Voltage and Consumption: 24-VAC, 10-VA, Class 2. One side can be grounded.

Operating Environment

Temperature: –40° to 158°F (–40° to 70°C)Humidity: 0%–95% Relative Humidity, non-condensing

Physical Dimensions

Height: 6 inchesWidth: 7.6 inchesDepth: 1.75 inchesWeight: Under 2 lb.

Module Communications

Communicates with Savvy®, Lingo®, and Envoi® using RS-485, 9600 baud.

Memory Backup

None (Factory default settings maintained in PROM)

Precautions

The following precautions should be taken during installation:

§ Observe national and local electrical codes.

§ Observe voltage and current limits marked on the module.

§ Do not connect 115 volts to any terminal of the TR-10. The TR-10 is a Class 2(low-voltage) control device.

§ Do not use the TR-10 as a final safety device.

Mounting theTR-10

Two options are available for mounting the TR-10:

§ Surface-mount

§ Mounting via optional Novar hinged mounting brackets

Mounting instructions for both methods are provided below.

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Surface-Mounting the TR-10

If the Trane rooftop unit control panel has enough room to mount the TR-10 withoutusing brackets, the following procedure should be used to mount it.

Step Procedure

1 Position the TR-10 against the mounting surface (as a template) and mark thelocation of the four mounting screw holes (see Figure 1).

2 Remove the TR-10 and drill holes in the locations marked.

3 Position the module against the mounting surface and insert and tightensuitable sheet metal screws to secure the module.

Mounting the TR-10 Using Hinged Mounting Brackets

If the module cannot be surface-mounted, Novar offers optional hinged mountingbrackets (see “Model and Part Numbers” in this document) that can be used to mount themodule. The following procedure should be used (refer to Figure 2, as necessary).

NOTE! If the rooftop unit does not contain a TCI-3 or Conventional ThermostatInterface (CTI), they must be added. This must be ordered from anauthorized Trane representative. The CTI is usually mounted to theback of the control panel next to the TCI module. Contact Trane forproper installation instructions.

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Figure 1. Mounting holes for the TR-10

Step Procedure

1 Attach the mounting brackets to the TR-10, using the screws provided with the brackets, so that the “foot” of the bracket faces the front of the module.

2 Determine the best location within the control panel for mounting the module.

§ This is usually at the bottom of the panel, front and center.

3 Position the module (on hinged brackets) against the mounting surface (as atemplate) and mark the location of the mounting holes.

4 Remove the module and drill holes at the locations marked.

CAUTION! Be careful not to drill into any wires.

5 Position the module against the mounting surface and insert and tighten themounting screws provided with the bracket to secure the module.

NOTE! To access the components that are behind the TR-10, remove the screwsthat are in the side of each mounting bracket and swing the TR-10forward and out of the way. The wiring connections all face up toaccommodate this procedure.

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Figure 2. TR-10 mounted to the hinged mounting brackets

Supplying theTR-10 with Power

The TR-10 requires 24-VAC power with a consumption rating of 10 VA. Connect the24-VAC to Terminals 31 and 32, labeled “24 VAC Module Power Input.”

NOTE! The 24-VAC power connection is isolated. One transformer can be used to power multiple modules within the restrictions of a 10 VAconsumption.

A single transformer can be used to power the TR-10 electronics and the TR-10 outputs, if desired. Make sure the transformer has sufficientcapacity.

Wiring the TR-10

Wiring connections can be made to either the removable screwed terminal strips, or tothe quick-connect connectors that accommodate pre-made wiring harnesses. Thequick-connect connectors are AMP series 640250. The screwed terminal strips and the quick-connect pins are in parallel.

When wiring connections to the TR-10, refer to Figure 3, as necessary.

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Figure 3. TR-10 wiring connections

Wiring the TR-10Inputs

Setpoint Adjust Potentiometer

A 10K-ohm potentiometer can be connected to the TR-10 to cause the heating andcooling setpoints to be adjusted ± 3 degrees (up to 3 degrees).

§ Connect the potentiometer’s wiper to TR-10 Terminal 1.

§ Connect the potentiometer’s counterclockwise wire to TR-10 Terminal 3.

Timed Override

An optional momentary contact push-button (switch) can be connected to initiate a timedschedule override.

§ Connect the switch to TR-10 Terminals 2 and 3.

Zone and Supply-Air Temperature Sensors

All three temperature sensors must be 10,000-ohm thermistors (Futura TemperatureSensors FTS-4 or FTS-4A, Precon Type II, or equivalent). When connecting thermistors, polarity does not matter.

§ Connect the two zone temperature sensors (one of them can be a return-air sensor) toTR-10 Terminals 4 and 5 and Terminals 6 and 7.

§ Connect the supply-air temperature sensor to TR-10 Terminals 8 and 9.

Airflow Status

The Air Flow Status Input is a dry contact, digital input.

§ Connect the Airflow Status Input to TR-10 Terminals 10 and 11 as normally openwith the contacts closing when the fan is on.

Filter Status

The Filter Status Input is a dry contact, digital input.

§ Connect the Filter Status Input to TR-10 Terminals 11 and 12 as normally open withthe contacts closing when the filter is dirty.

TCI Network Communications

The TCI network requires a three-wire communications bus (plus, minus, and ground;use Novar WIR-1010, Belden 8761, or equivalent).

§ Connect TCI (+) to TR-10 Terminal 16.

§ Connect TCI (–) to TR-10 Terminal 18.

§ Connect TCI ground reference to TR-10 Terminal 17.

TCI Board Configuration

The TCI board contains the following items that must be adjusted for properconfiguration:

§ A plug-in daughter board that can be rotated to configure various Tranecommunication protocols.

§ Dip switches (located above the daughter board) that must be set for propercommunications.

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The following procedure should be used to configure the TCI board.

Step Procedure

1 Rotate the daughter board so that the connector for “Non-isolated Com 3 orCom 4” is facing the bottom of the TCI and the connector for “Isolated Com3” is on the right side of the TCI.

2 Set Switches 2–6 to different positions.

§ All switches cannot be in the same position. (Turn some of them on andsome of them off.)

§ Switch 1 is not used in addressing. It is the High Temperature Enableswitch. Leave this switch as you found it.

Wiring the TR-10Outputs

NOTE! The TR-10 accommodates separate power sources for the heating andcooling sections of the rooftop unit. If just one control transformer isused, a jumper must be installed between Terminals 29 and 30.

The TR-10 provides seven digital outputs at Terminals 19 through 28 (see Figure 3). The TR-10 outputs connect to the LTB low voltage terminal strip of the Trane Rooftop Unit. Figure 4 shows the relay contacts wiring connections and operation.

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19 Economizer Normally Open20 Economizer Common21 Economizer Normally Closed

22 Nite Mode Contact23 Nite Mode Contact

24 Cool 125 Cool 226 Fan27 Heat 128 Heat 229 Control 24-VAC for C1/C2/Fan

Field-installed jumper, if necessary30 Control 24-VAC for H1/H2

OPERATIONTERM.

NO.RELAY CONTACTS

{Refer to the Economizerwiring instructions

Figure 4. TR-10 relay contacts wiring connections and operation

Economizer (Damper) Wiring

The damper relay is a Form C (normally open and normally closed) relay that is isolatedfrom the other contacts. It does not source 24 volts unless it is provided to this relay.

There are several ways to wire the economizer damper on a TR-10. With most Traneunits, the recommended method of initiating economizer cooling is to create a simulatedoutdoor-air temperature reading that will cause the Trane control system to initiateeconomizer cooling. To do this, the Trane Outdoor Temperature Sensor (OTS) must bewired through the TR-10 normally closed damper contact. When the TR-10 calls for thedamper output, it disconnects the Trane OTS and puts a resistor into the circuit thatsimulates 45°F. At the same time, it energizes the Cool 1 output relay. This causes theTrane control system to open the damper and modulate it to maintain a 55°F discharge-air temperature. If the zone temperature continues to rise, the TR-10 may call for Cool 2,which will bring on one compressor to supplement the economizer cooling. Figure 5shows the wiring used to simulate an outdoor-air temperature to call for economizercooling.

Economizer Relay Jumper Settings

NOTE! Normal TR-10 economizer control energizes the damper and coolingrelays at the same time to interface properly with Trane RTUs. Tooperate in this mode, the jumper for the damper output (JP1) is set to45°F or 30°F. When the damper output is on (open), Cool 1 will not bedisplayed on the ESS32 or iScope monitoring screens because theeconomizer damper is acting as the first stage of cooling.

If the space temperature rises and the outside air temperature is withinan acceptable range, Cooling 2 will turn on mechanical cooling tosupplement the economizer. Under this condition, the monitoring screen will indicate that the damper and Cool 2 are on (not Cool 1)

There is a jumper on the circuit board of the TR-10 labeled “JP1.” To have the TR-10simulate 45°F outside-air temperature, the jumper should be placed on the bottom twopins (Pins 1 and 2).

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UCP

19

20

21

JP1JUMPERS

N.O.

N.C.

30°

45°

OTS

Figure 5. Wiring the TR-10 to simulate an outdoor-air temperature to call foreconomizer cooling

The wiring scheme shown in Figure 3 should be used, but the JP1 jumper should be puton Pins 2 and 3 to simulate an outside-air temperature of 30°F. This simulatedtemperature setting is recommended for use with Trane Heat Pump RTUs. The 30°Fsetting causes the heat pump to go into a compressor protection mode. If the compressoris required to maintain a 55°F discharge-air temperature, it will occasionally cycle off. This is a Trane default mode for heat pumps, and the control is executed by the Tranecontrol system.

If the damper relay needs to be used simply as a contact closure (i.e., not to simulate anoutside-air temperature), the JP1 jumper should be placed on Pins 4 and 5.

NOTE! During economizer cooling, both the damper and Cool 1 relays will beenergized.

Nite Mode Damper

The Nite Mode Damper contacts are isolated from the other outputs and do not source 24VAC. These contacts are used to bypass the dampers minimum position potentiometerduring scheduled off time to cause the damper to close fully when the building isunoccupied.

NOTE! The TR-10 contains a 1-amp, 3-AG fuse that can be removed to disableautomatic control of the outputs for testing.

NetworkCommunications

A suitable two-conductor cable with shielded ground (Novar WIR-1010, Belden 8761, or equivalent) should be used to make the communication connections between the TR-10and the module communication terminals of the system’s executive module (Savvy,Lingo, or Envoi).

On the TR-10, the connections are Terminals 13, 14, and 15. Make certain that thepositive (+) and negative (–) connections are made to the correct terminals on the TR-10and the executive module.

CAUTION! The shield connection is not a ground. It is dedicated forcommunications only. Do not connect any other grounds to theShield connection (Terminal 14).

Setting the Module Address Switches

Every Logic One module must have a unique address for the executive module toidentify it. Addresses are assigned in the software during system programming. Thesystem printout will show the address of the TR-10 being installed.

The address switch is located in the upper right corner of the shield (see Figure 3). Setthe switches to match the address as indicated in Figure 6 and record the settings on theaddress label on the shield.

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NOTE! The address switches should only be changed while the TR-10 ispowered down.

Address 00 may not be used by the TR-10 when operating on a Savvy. (The IOM section uses address 00.)

Model and PartNumbers

The part numbers shown in Table 1 should be used to order the necessary Novar parts.

Table 1. Novar Part Numbers

PRODUCT MODEL NO. PART NO.

TR-10 Trane® RTU System Enhancer TR-10 736015000

Hinged Mounting Brackets for the TR-10 (Optional) — 736015100

Two-Conductor Cable with Shielded Ground (Belden8761 equivalent)

WIR-1010 709001000

TR-10 wiring harness — 736015200

Futura Temperature Sensor FTS-4 732503000

Futura Temperature Sensor with temperatureadjustment potentiometer

FTS-4A 732501000

Futura Adapter Plate with threaded inserts FTS-BPL 732900000

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Figure 6. Setting the module address

RegulatoryCompliance

Safety

This device has been tested and found to be in compliance with the requirements set forth in UL 916, Energy Management Equipment, and is listed by Underwriters Laboratories, Inc., for installations in the United States.

This device has been tested and found to be in compliance with the requirements set forth in C22.2, No. 205-M1983, Signal Equipment, and is Certified by Underwriters Laboratories,Inc., for installations in Canada.

ElectromagneticCompatibility (EMC)

Federal Communications Commission (FCC)

This device complies with Part 15 of the FCC Rules. Operation is subject to the followingtwo conditions: (1) This device may not cause harmful interference, and (2) This devicemust accept any interference received, including interference that may cause undesiredoperation.

NOTE! This device has been tested and found to comply with the limits establishedfor Class A digital devices. It is intended to be used in a commercialenvironment. Operation of this equipment in residential environments maycause harmful interference, in which case the user may be required tocorrect the interference at his own expense.

CAUTION! Any changes or modifications not expressly approved by Novar ControlsCorporation could void your authority to operate this equipment.

Industry Canada

This digital apparatus does not exceed the Class A limits for radio noise emissions fromdigital apparatus set out in the interference-causing equipment standard entitled DigitalApparatus, ICES-003, of Industry Canada.

Cet appareil numérique respecte les limites de bruits radioélectriques applicables auxappareils numériques de Classe A préscrites dans la norme sur le matériel brouiller:Appareils Numériques, NMB-003, édictée par l’Industrie Canada.

Logic One®, Savvy®, Lingo®, Envoi®, and iScope® are registered trademarks of Novar.Trane® is a registered trademark of Trane.

Voyager™, and ReliaTel™ are trademarks of Trane.MODBUS® is a registered trademark of Schneider Electric.

The material in this document is for information purposes only. The contents and the product it describes aresubject to change without notice. Novar makes no representations or warranties with respect to this document.In no event shall Novar be liable for technical or editorial omissions or mistakes in this document, nor shall it beliable for any damages, direct or incidental, arising out of or related to the use of this document. No part of this

document may be reproduced in any form or by any means without prior written permission from Novar.

Printed in Mexico.

Copyright © 2007 by Honeywell International, Inc.. All Rights Reserved.

Novar; 6060 Rockside Woods Blvd., Cleveland, OH 44131Tel.: 800.348.1235 www.novar.com

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Notes

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