Trane Technologies Tracer AH541 Bedienungsanleitung

Tracer™ AH541 Version 2

Air-Handler Controller Hardware

Installation Guide

April 2020 CNT-SVN02D-EN

SAFETY WARNING

Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of

heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.

Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.

When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are

attached to the equipment.

Introduction

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper

operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

CAUTIONsIndicates a potentially hazardous situation which, if not avoided, could result in

minor or moderate injury. It could also be used to alert against unsafe practices.

NOTICE Indicates a situation that could result in equipment or property-damage only

accidents.

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally

occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the

identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine

and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all

refrigerants containing these compounds have the same potential impact to the environment.

Trane advocates the responsible handling of all refrigerants-including industry replacements for

CFCs and HCFCs such as saturated or unsaturated HFCs and HCFCs.

Important Responsible Refrigerant Practices

Trane believes that responsible refrigerant practices are important to the environment, our

customers, and the air conditioning industry. All technicians who handle refrigerants must be

certified according to local rules. For the USA, the Federal Clean Air Act (Section 608) sets forth the

requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the

equipment that is used in these service procedures. In addition, some states or municipalities may

have additional requirements that must also be adhered to for responsible management of

refrigerants. Know the applicable laws and follow them.

WARNING

Proper Field Wiring and Grounding Required!

Failure to follow code could result in death or serious injury. All field wiring MUST be

performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE

and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field

wiring installation and grounding as described in NEC and your local/state electrical codes.

Failure to follow code could result in death or serious injury.

WARNING

Personal Protective Equipment (PPE) Required!

Failure to wear proper PPE for the job being undertaken could result in death or serious injury.

Technicians, in order to protect themselves from potential electrical, mechanical, and chemical

hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well

as the instructions below:

• Before installing/servicing this unit, technicians MUST put on all PPE required for the work

being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard

hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to

appropriate Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.

• When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS

and OSHA/GHS (Global Harmonized System of Classification and Labeling of Chemicals)

guidelines for information on allowable personal exposure levels, proper respiratory

protection and handling instructions.

• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE

in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash

protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING,

DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC

FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED

FOR INTENDED VOLTAGE.

WARNING

Follow EHS Policies!

Failure to follow instructions below could result in death or serious injury.

• All Trane personnel must follow the company’s Environmental, Health and Safety (EHS)

policies when performing work such as hot work, electrical, fall protection, lockout/tagout,

refrigerant handling, etc. Where local regulations are more stringent than these policies,

those regulations supersede these policies.

• Non-Trane personnel should always follow local regulations.

Introduction

CNT-SVN02D-EN 3

This document and the information in it are the property of Trane, and may not be used or

reproduced in whole or in part without written permission. Trane reserves the right to revise this

publication at any time, and to make changes to its content without obligation to notify any person

of such revision or change.

Trademarks

All trademarks referenced in this document are the trademarks of their respective owners.

Table of Contents

4CNT-SVN02D-EN

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Agency listing/compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installing the frame-mounted Tracer AH541 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Enclosure requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installing the termination board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mounting the enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Selecting a mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operating environment requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mounting the enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Wiring high-voltage ac power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Local power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Circuit requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Wiring high-voltage power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installing the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Installation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Checking the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wiring inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Required inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Input/output wiring guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Wire routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Screw-terminal locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Binary outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Zone sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Binary inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installing the circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

To install the circuit board: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Table of Contents

CNT-SVN02D-EN 5

Installing the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Removing the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Installing the stand-alone operator display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Connecting the portable operator display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Setting up the operator display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Setting up time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Calibrating the operator display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Adjusting brightness and contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Verifying operation and communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Test button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Performing a manual output test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Service Pin button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Interpreting LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Interpreting diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Checking the earth ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6CNT-SVN02D-EN

Overview

This guide shows how to install the Tracer AH541 air-handler controller.

Product description

The Tracer AH541 air-handler controller is a low-cost, direct digital controller. It controls a wide

variety of air-handlers and offers the following features:

• Factory programming of many unit configurations and sequences of operation simplifies

installation and brings consistency to the air-handler controllers on a site

• Interoperability through Comm5 communications. (Comm5 is Trane’s implementation of

LonTalk®.)

• Support of the LonMark® Space Comfort Controller (SCC) profile and the Discharge Air

Controller (DAC) profile for air-handlers

• Operates as a stand-alone device, as part of a peer-to-peer network, or as part of a building

automation system (BAS)

Specifications

The Tracer AH541 conforms to the specifications shown in Table 1.

Table 1.

Dimensions

(see Figure 5 on page 9 for

dimensional drawing)

16 ½ in. × 14 ¾ in. × 5 ½ in.

(418 mm × 373 mm × 140 mm)

Weight 15 lb (7 kg)

Operating temperature

Without display: From –40°F to 158°F 

(–40°C to 70°C)

With display: From 32°F to 122°F (0°C to 50°C)

Storage temperature

Without display: From –40°F to 185°F 

(–40°C to 85°C)

With display: From –13°F to 149°F 

(–25°C to 65°C)

Humidity 5–95% non-condensing

Altitude 6500 ft (2000 m)

Installation Category 3

Pollution Degree 2

High-voltage power

requirements

North America: 98–132 Vac, 1 A maximum, 1 phase

Other: 196–264 Vac, 1 A maximum, 1 phase

Tracer AH541 specifications

CNT-SVN02D-EN 7

Overview

Agency listing/compliance

UL and C-UL:

UL 916 Energy Management

CUL C22.2 No. 205-M1985 Signal Devices

FCC:

CFR 47, Part 15, Subpart A, Class A

CE:

Emissions

EN55022 Class B

EN61000-3-2

EN61000-3-3

Immunity

EN50082-2 Industrial

Additional components

The Tracer AH541 controller requires additional components for certain applications and has

several options for adding an operator display.

Power transformer

The frame-mounted Tracer AH541, which ships without an enclosure, requires a UL-listed Class 2

transformer providing 70 VA at 24 Vac.

Operator display

The operator display is available in three models (see Figure 1, p. 8):

• Door-mounted operator display

• Stand-alone operator display, for mounting on a wall up to 150 ft (46 m) from the controller

• Portable operator display

8CNT-SVN02D-EN

Overview

Figure 1. Operator display models

Door-mounted operator display Stand-alone operator display Portable operator display

Required tools

To install the Tracer AH541 controller and check it for proper operation, you will need the following

tools:

•Drill

• Phillips-head screwdriver

• Small flat-tip screwdriver (for terminal screws)

• Digital multi-meter

CNT-SVN02D-EN 9

Installing the frame-mounted Tracer AH541

This section applies only to the frame-mounted Tracer AH541 controller. The frame-mounted

Tracer AH541 can be used to replace older controllers in existing equipment or can be mounted in

new equipment or custom enclosures.

Enclosure requirements

Before installing the frame-mounted Tracer AH541, make sure that the enclosure or mounting

space meets the following minimum requirements:

• Minimum clearances as shown in Figure 2

• 24 Vac dedicated power supply

• Compliance with National Electrical Code and applicable local electrical codes for high-voltage

power wiring to the enclosure

Note: The Tracer AH541 with enclosure is mounted in a National Electrical Manufacturers

Association (NEMA) 1 enclosure. To meet NEMA 4 specifications, you can order the frame-

mounted Tracer AH541 (model BMTA000CA0A0) and mount it in a separately purchased

NEMA 4 enclosure.

Figure 2. Frame-mounted Tracer AH541 minimum clearances

BO5

BO4

BO3

BO2

BO1

BO6

24VAC

AO4

AO3

AO6

AO5

AO2

IN3

IN2

IN1

AO1

IN6

IN7

IN5

IN11

IN12

IN10

IN9

IN8

IN4

½ in. (13 mm)

3 in. (76 mm)

for communications wires

6 in. (152 mm)

for I/O wires

½ in. 

(13 mm)

10 CNT-SVN02D-EN

Installing the termination board

To install the termination board in a separately purchased enclosure or in other equipment:

1. Remove the controller from its packaging and separate the top and bottom frames.

2. Using the bottom frame (with the termination board) as a template, mark the location of the four

mounting holes on the mounting surface (see Figure 3).

Figure 3. Frame-mounted dimensions and mounting holes

3. Set the controller aside and drill holes for #8 (4 mm) screws at the marked locations.

4. Secure the controller to the mounting surface with #8 (4 mm) screws (not supplied).

To install input/output wires, the main circuit board, and other components, follow the instructions

in the following sections.

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