Contents Introduction ..................1 Supported Products ................2 Packaged Climate Changer™ Air Handling Units........ 2 Modular Climate Changer™ Air Handling Units........2 T-Series Climate Changer™ Air Handling Units ........2 Features ....................3 Termination board ................4 Controller board .................5 Physical specifications ..............6 Board dimensions ................6 Termination board..............
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Contents Outdoor air temperature ..............18 Mixed air temperature ..............18 Duct static pressure................18 On/cancel buttons................19 Zone sensor ..................20 Space temperature measurement ............ 20 Zone sensor setpoint adjustment ............. 20 Fan mode switch ................22 On/cancel buttons................22 Zone sensor communication jack .............
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Contents Variable air volume control ..............45 Duct static pressure control ............45 Supply fan operation................45 Constant volume operation .............46 Variable air volume operation ..........46 Valve operation ..................46 Steam valve cycling..............47 Face and bypass damper operation...........47 Outdoor air damper operation ............48 Mixed air temperature control..........48 Economizer operation..............49 Low ambient damper lockout..........50 Exhaust fan operation................50...
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Contents Test push button..............64 Service push button..............64 Green Status LED ..............65 Yellow Comm LED ..............65 Manual output test................65 Test sequence ................ 66 Minimum timers ..............67 Required inputs for unit operation ............ 67 Diagnostics ..................67 Translating multiple diagnostics..........
The configurable air handling unit controller is also available as the Tracer AH.541 field-installed air handling unit controller (St. Paul, Minnesota). The features and functions of the Tracer AH.541 are identical to those of the Tracer AH.540 described in this manual. CNT-SVX05A-EN...
™ T-Series Climate Changer Air Handling Units The Tracer AH.540 controller availability on the T-Series Climate Changer air handlers is limited to the features and functions provided by the controller. See the Features section for more information. Manufacturing Location: Lexington, Kentucky...
Features ™ Table 1 — Tracer AH.540 features and control modes Constant volume space Constant volume Variable air volume temperature control discharge air control control Fan control On/Off On/Off Variable Duct static pressure con- trol Hydronic cooling Hydronic heating Steam heat Face and bypass heating X Ventilation control Economizer damper...
Termination board Analog Outputs Binary Outputs Analog Inputs Power Comm 5 Communication Terminals Duct Static Pressure Input Binary Inputs CNT-SVX05A-EN...
Controller board RED Service LED Supply Fan Service Push Button Status LED Yellow Comm LED Test Push Button Exhaust Fan Green Status LED Status LED ID Label CNT-SVX05A-EN...
TB25-2 BO 6 Not used TB26-1 Not used Not used (Note 1) TB26-2 Note 1: Terminals BO 3, BO 4, BO 5, and BO 6 do not serve any function of the Tracer AH.540 controller and are not used. CNT-SVX05A-EN...
Physical specifications Analog outputs The analog outputs are 0 to 10VDC. Table 3 — Analog outputs Description Function Factory Field Label Terminal Maximum terminals terminals function output rating AO 1 Supply fan TB11-1 0 to 10VDC 20mA speed TB11-2 Ground AO 2 Cool output TB12-1...
Physical specifications Binary inputs Each binary input associates an input signal of 0VDC with closed contacts and 24VDC with open contacts. If the wired binary device has closed contacts, a multimeter should measure less than 1.0VDC across the binary input terminals. If the binary input has opened, a multimeter should measure greater than 20VDC across the binary input terminals.
Analog and binary outputs The Tracer AH.540 is configured at the factory per unit configuration and order information. The controller is applied to air handling product configurations supporting analog modulating valves, economizer damper, and face and bypass damper. The controller supports a constant volume or variable air volume supply fan.
Not Used. The Tracer AH.540 controller has six available binary inputs. The binary inputs are connected to the Tracer AH.540 terminal board on inputs IN 7 through IN 12. Normally these inputs are factory-configured for the following functions.
Low temperature detection protects the coils of hydronic units. A low temperature detection device (freezestat) connected to binary input IN 7 detects the low temperature. The Tracer AH.540 controller can protect the coil using one binary input. When the controller detects the low temperature detection signal, the controller generates a diagnostic which disables the fan, opens all unit water or steam valves, and closes the outdoor air damper (when present).
Binary inputs Occupancy The Tracer AH.540 controller uses the occupancy binary input IN 9 for two occupancy-related functions. Standalone For standalone controllers (any unit not receiving a communicated occupancy request, typically from a building automation system), the occupancy binary input determines the unit's occupancy based on the hardwired signal. Normally, the signal is hardwired to a binary switch or clock.
Filter status The filter status switch connected to binary input IN 11 detects a dirty air filter and indicates a need for maintenance. For Tracer AH.540 applications, a differential pressure switch detects filter status, with the high side of the differential being supplied at the filter inlet and the low side supplied at the filter outlet.
Binary inputs Exhaust fan status The exhaust fan status binary input IN 12 indicates the presence of air flow through an exhaust fan associated with the controlled air handling unit. For Tracer™ AH.540 applications, a differential pressure switch detects exhaust fan status, with the high side of the differential being supplied at the outlet.
Tracer AH.540 interprets the signal as a timed override On request. The Tracer AH.540 uses the timed override On request (while the zone is unoccupied) as a request to go to the occupied bypass mode (occupied bypass).
Communicated setpoint setpoint input sensor thumb wheel Note 1: Communicated inputs to the Tracer AH.540 controller have precedence over locally wired inputs. Fan mode switch The fan mode analog input IN 3 responds to specific resistances corresponding to a fan mode switch provided with certain Trane zone sensors. The fan mode switch on a Trane zone sensor generates the fan mode signal.
If the sensor returns to a valid input, the controller automatically allows the unit to resume operation. The Tracer AH.540 controller uses analog input 4 (IN 4) as the discharge air temperature input with a 10kΩ thermistor only. This sensor is hardwired and located downstream from all unit heating/cooling capacity at the unit discharge area.
On/cancel buttons Momentarily pressing the On button during unoccupied mode places the controller in occupied bypass mode for 120 minutes. You can adjust the number of minutes the Tracer AH.540 is placed in the occupied bypass mode using ™ Rover service tool.
• Service pin message request Space temperature measurement Trane zone sensors use a 10kΩ thermistor to measure the space temperature. Typically, zone sensors are wall-mounted in the room and include a space temperature thermistor. A valid space temperature input is required for the controller to operate in constant volume space temperature control.
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Zone sensor The controller adds the absolute setpoint offset to occupied and occupied standby default setpoints to derive the effective setpoints as follows: Unoccupied cooling setpoint 85°F (same as default) Occupied standby cooling setpoint 77°F (default+1=77) Occupied cooling setpoint 75°F (default+1=75) Occupied heating setpoint 71°F (default+1=71) Occupied standby heating setpoint...
Auto fan mode of operation. On/cancel buttons Some Trane zone sensor modules include timed override On and Cancel buttons. Use the timed override On and Cancel buttons to place the controller in override (occupied bypass mode) and to cancel the override request.
Zone sensor Zone sensor wiring connections Table 18 — Typical Trane zone sensor wiring connections with a fan mode switch Description Space temperature Common setpoint Fan mode Communications Communications Table 19 — Typical Trane zone sensor wiring connections without a fan mode switch...
Comm5 devices are given a unique address by the manufacturer. This address is called a Neuron ID. Each Tracer AH.540 controller can be identified by its unique Neuron ID, which is printed on a label on the controller’s logic board. The Neuron ID is also displayed when communication is established using Tracer Summit or Rover service tool.
Communications Wire characteristics UCM communication-link wiring must be low capacitance, 18-gauge, shielded, twisted pair with stranded, tinned-copper conductors. For daisy chain configurations, limit the wire run length to 5,000 ft (1524 m). Trunk and branch configurations are significantly shorter (see Figure 3). Comm5 wire length limitations can be extended through the use of a link repeater.
• If the link contains more than one type of wire, the link will probably have to be manually tuned. Trane recommends that only one type of wire be used for the Comm5 communication link •...
The following guidelines should be followed while installing communication wire. • Comm5 is not polarity sensitive. Trane recommends that the installer keep polarity consistent throughout the site • Only strip away 2" maximum of the outer conductor of shielded cable •...
Power input from control box 24VAC transformer TB1-2 TB1-3 24VAC Accessory 24VAC power to other devices TB1-4 TB1-5 24VAC Accessory 24VAC power to other devices TB1-6 Figure 6 — Tracer AH.540 power requirement Line Voltage 24 VAC Termination Board Transformer (factory supplied) Chasis Ground AHU Controller...
Input/output summary The controller includes the following input and output points: Power 24VAC NEC Class 2 Two binary outputs Supply fan start/stop (BO 1) Exhaust fan start/stop (BO 2) Five analog outputs Supply fan speed (AO 1) Cool output (AO 2) Heat output (AO 3) Face and bypass damper (AO 4) Outdoor air damper (AO 5)
The factory default settings are also based on the air handling unit configuration and order information. The Tracer AH.540 controller is configurable to operate in one of three air handling modes of operation: • Constant volume space temperature control •...
Sequence of operation If a space temperature input is provided to the controller when configured as constant volume discharge air control or variable air volume control, the controller uses the space temperature to perform morning warm-up and daytime warm-up functions. Morning or daytime warm-up functions allow the controller to automatically change to heating if space temperature is less than the heating setpoint.
Sequence of operation Space temperature setpoint operation The controller has three sets of possible heating and cooling setpoints: • Occupied • Occupied standby • Unoccupied In unoccupied mode, the controller always uses locally stored default unoccupied heating and cooling setpoints. These setpoints are configured at the factory prior to shipment.
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Sequence of operation The hardwired setpoint is used with the controller's occupancy mode (occupied, occupied standby, or unoccupied), the heating or cooling mode, the temperature deadband values, and the heating and cooling setpoints (high and low limits) to determine the controller's active setpoint Example continued: Assume a thumbwheel setpoint input of 73°F, resulting in an absolute setpoint offset of 1°F (73–72=1).
The occupancy mode can be hardwired to the controller via the occupancy binary input or communicated to the controller. Occupied mode The Tracer AH.540 controller operates according to the configured control mode: • Constant volume space temperature control • Constant volume discharge air temperature control •...
In unoccupied mode the supply fan is off whenever the space temperature is between the unoccupied heating and cooling setpoints. If the space temperature rises above the unoccupied cooling setpoint the Tracer AH.540 turns on the supply fan and provides cooling at the discharge air cooling setpoint.
Occupancy—manual command Some communicating devices may request occupancy based on the information communicated in the network variable nvoOccManCmd. Trane systems and zone ™ sensors do not communicate this information to the controller, but the Tracer AH.540 controller accepts this network variable as communicated input nviOccManCmd.
Note 4: If the occupied bypass timer is not equal to zero, the effective occupancy will be occupied bypass. On and Cancel buttons on the zone sensor Some Trane zone sensor modules include timed override On and Cancel buttons. Use the timed override On and Cancel buttons to place the controller in override (occupied bypass mode) and to cancel the override request.
Auto, the controller compares the active space setpoint and the active space temperature and decides if the space needs heating or cooling. The Tracer AH.540 controller must have a valid space temperature and discharge air temperature input to operate constant volume space temperature control.
Sequence of operation The capacity calculation, as a result of the discharge air control loop, is used to drive the air handling unit's actuators to maintain space temperature at the space temperature setpoint. Figure 7 — Space temperature control block diagram →...
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Auto mode, the unit switches to the desired mode based on the control algorithm. If the Tracer AH.540 controller is operating space temperature control, it uses the space temperature and space temperature setpoint to automatically determine heat or cool mode of operation.
Sequence of operation Figure 8 — Automatic heat/cool changeover logic example This is the point at which the cooling capacity equals 0%, space temperature is less than 0.5° F below the cooling setpoint, and the error integrator starts to add up. Error integration does not begin until the capacity is 0%.
Figure 9 shows the steps the Tracer AH.540 controller takes to control discharge air. First the controller determines if a communicated discharge air heating setpoint and discharge air cooling setpoint are present.
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Sequence of operation The effective discharge air temperature setpoint is determined from: • communicated or configured discharge air setpoint value • minimum and maximum heat/cool setpoint limits • the effective heat/cool mode Example: Table 24 — Configuration parameters 55 ° F Discharge air cooling setpoint 68 °...
Sequence of operation Figure 9 — Discharge air temperature control flow diagram → Configured value: The communicated heat/cool setpoint value has discharge air heating setpoint precedence over the configured discharge air discharge air cooling setpoint temperature heat/cool setpoint → Communicated value: discharge air heating setpoint Discharge air heating Discharge air cooling...
When a supply fan status binary input sensor is wired to the controller (IN 10) it is used to verify fan operation before heating and cooling start. Upon energizing the supply fan output (BO 1) the Tracer AH.540 controller waits a configurable time period (fan status delay) to allow the fan time to reach a desired air flow.
If the controller is wired to a Trane zone sensor, the user can change the supply fan operation through the fan mode switch (when present). When the fan mode switch is in the Off position, the controller shuts down the unit.
(40°F default) at which the controller changes over to face and bypass heating operation. The face and bypass heat modulation setpoint can be changed using the Trane Rover™ service tool. When the outdoor air temperature is greater than 3°F above the face and bypass heating modulation setpoint, the hydronic heating valve is modulated to maintain discharge air temperature.
Default minimum damper positions are provided and can be changed using Trane's Rover service tool for occupied and occupied standby ventilation. The controller can also receive a communicated outdoor air damper minimum ™...
(either hardwired or communicated) or a communicated Enable command from ™ Tracer Summit , the Tracer AH.540 controller uses the modulating economizer damper as the highest priority source of free cooling. Economizing is possible during the occupied, occupied standby, unoccupied, and occupied bypass modes.
Sequence of operation Table 29 — Relationship between outdoor temperature sensors and damper position Outdoor air damper Outdoor air temperature Occupied or Occupied standby Unoccupied Occupied bypass No or invalid outdoor Open to occupied Open to occupied Closed air temperature minimum position standby minimum position...
Constant volume discharge air control or variable air volume control In these modes, the Tracer AH.540 controller requires a space temperature input (hardwired or communicated) and setpoint input (hardwired, communicated, or default value) to initiate the morning warm-up sequence of operation.
(hydronic or steam) and Tracer AH.540 is configured for: • constant volume discharge air temperature control • variable air volume control. A communicated or wired space temperature is required for the Tracer AH.540 to initiate daytime warm-up. Daytime warm-up forces the controller into heating when the space temperature is below the effective heating setpoint by a temperature that is more than the configured daytime warm-up enable differential.
Example: The Tracer AH.540 is not able to run the air handling unit because the run/stop input is set to stop (supply fan is off). If the outdoor air temperature is below the freeze avoidance setpoint, the Tracer AH.540 opens all water valves.
Sequence of operation Duct static pressure (when present) is always controlled when the supply fan is running. Freeze avoidance in emergency override can force the heating and cooling valves open. Water valve override To support water balancing, the controller includes a communication variable (nviValveOverride) that allows a user to specify the desired state of all water valves.
Calibration With Rover™ service tool, you can calibrate two of the controller’s analog inputs: space temperature, and setpoint. For each input, the calibration value is added to the measured value to determine the effective value. CNT-SVX05A-EN...
Normally closed Normally closed Note 1: Trane’s Rover service tool uses the unit type to determine and download the proper default analog output configuration. For example, if you configure the controller's control mode to be constant volume space temperature control, Rover will not allow AO 1 to be configured for a supply fan speed output. Analog output 1 (AO 1) is only used when the controller is configured for variable air volume control.
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Outdoor air temp IN 6 Mixed air temp Duct static Duct static pressure Note 1: Trane’s Rover service tool uses the unit type to determine and download the proper default analog input configuration. Table 35 — Binary inputs Binary input Function...
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Disharge temperature setpoint low limit (Note 1) (1.7 to 65.6 ° C) Note 1: When the Tracer AH.540 controller is configured for constant volume space temperature control (control mode), the control algorithm is limited to calculating this high and low discharge air temperature setpoint.
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Configuration Table 43 — Duct static pressure Parameter Valid range Default value Duct static pressure high limit (Note 1) 0 to 5 inches WC 4 inches WC (0 to 1250 Pa) (1000 Pa) Duct static pressure setpoint 0 to 5 inches WC 1.5 inches WC (0 to 1250 Pa) (375 Pa)
Configuration Table 48 — Steam valve cycling Parameter Valid range Default value Time period 0 to 10 minutes 5 minutes Duty cycle (Note 1) 0 to 100% Valve open position (Note 2) 0 to 100% Note 1: Duty cycle is the percentage of the time period the steam valve is open. Note 2: The steam valve open position can be set to a partially open position to prevent excessive steam coil temperatures.
Application information Standalone Occupied/unoccupied You can configure the controller's binary input (IN 9) as an occupancy input to switch between occupied and unoccupied modes of operation. When IN 9 is configured as a normally open occupancy input, the standalone controller switches to occupied mode when IN 9 contacts are open.
Application information Standalone peer-to-peer ™ Tracer AH.540 controllers allow peer-to-peer (also referred to as master/slave) data communication. Data such as space temperature, setpoint, and occupancy can be shared from a master control to a peer control with or without the ™...
You can achieve this by wiring the adjustable setpoint (typically included as a part of the Trane zone sensor module) to one controller—defined as the master. Next, use Rover™ to set up the master and one or more slaves to share that setpoint.
Troubleshooting Red Service LED Table 51 — Red Service LED activity Red LED Activity Description LED is off continuously after power Normal operation. is applied to the controller. LED is on continuously, even when Someone is pressing the Service push button or power is first applied to the controller.
Troubleshooting Green Status LED The green Status LED is normally used to indicate whether or not the controller is powered On (24VAC). Table 52 — Green Status LED activity Green LED activity Description LED is on continuously. Power on (normal operation). LED blinks (one blink).
Face and bypass full bypass 7: Exit (Note 4) Note 1: The following diagnostics cause the Tracer AH.540 to exit manual output test: • Duct Static Pressure High Limit • Low Supply Fan Air Flow • Low Temp Detect •...
Service required The controller disables certain sequences of operation only and attempts to maintain unit operation. For example, if the mixed air temperature sensor fails or is not wired, the Tracer AH.540 controller disables (does not allow) economizer operation. Informational This type of diagnostic does not affect controller operation.
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Troubleshooting Table 56 – (continued) Controller diagnostics Diagnostic or Condition Control type Supply Other outputs configuration (Enabled = Normal Operation) Low Exhaust Fan Air Flow CV Space temp control Enabled Valves Enabled (service required) CV Discharge air control Outdoor air damper Enabled Variable air volume control Face and bypass damper Enabled Exhaust fan Off...
Troubleshooting Translating multiple diagnostics The controller senses and records each diagnostic independently of other diagnostics. It is possible to have multiple diagnostics present simultaneously. The diagnostics are reported in the order they occur. Each diagnostic has a priority. When two diagnostic conditions exist, one diagnostic has priority over the other.
Troubleshooting Resetting diagnostics A reset clears any latching diagnostics and allows the controller to try to run the air handling unit normally. If the latching condition is still present, the controller immediately shuts down the air handling unit. A reset will restart a unit that is running normally.
Fan mode off When a local fan mode switch (provided on the Trane zone sensor) determines the fan operation, the off position controls the unit off. Requested mode off You can communicate a desired operating mode (such as off, heat, and cool) to the controller.
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Refer to the Manual output test section. Fan mode off When a local fan mode switch (provided on the Trane zone sensor) determines the fan operation, the Off position controls the unit off and closes the valves.
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Troubleshooting Table 62 — Outdoor air damper stays closed Probable cause Explanation Normal operation The controller opens and closes the outdoor air damper based on the control- ler's occupancy mode and fan operation. Normally, the outdoor air damper is open during occupied, occupied standby, and occupied bypass mode when the fan is running and closed during unoccupied mode unless the controller is economizing.
Appendix Appendix Table 63 — Constant volume space temperature control operation based on the effective heat/cool output Application Heat/cool mode input Effective heat Unit Operation mode input (nviHeatCool) cool mode output (nviApplicMode) (nvoHeatCool) Auto Auto Determined by Fan Enabled controller Heating Enabled Cooling Enabled Damper Enabled...
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Appendix Table 62 — (continued) Constant volume space temperature control operation based on the effective heat/cool output Application Heat/cool mode input Effective heat mode input (nviHeatCool) cool mode output (nviApplicMode) (nvoHeatCool) Unit Operation Auto Not present Determined by Fan Enabled controller Heating Enabled Cooling Enabled...
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Heating Enabled Cooling Disabled Damper Enabled Note 1: Heating capacity can be used to control the discharge air temperature to the discharge air cooling setpoint. Table 65 — Trane zone sensor module hardwired setpoint adjustment Resistance setpoint 889.4 Ω 50 ° F 733.6 Ω...
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Appendix Table 66 — Hardwired 10k Ω thermistor values Resistance Temperature Resistance Temperature 87.5k Ω 0 ° F 10.0k Ω 77 ° F 74.6k Ω 5 ° F 9.3k Ω 80 ° F 63.8k Ω 10 ° F 8.2k Ω 85 °...
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Appendix CFR 47, Part 15, Subpart A, Class A Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
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Index Active setpoint ..................... 33 Address of Comm5 devices ................24 AH.540 Analog inputs....................8 Analog outputs .....................8 Binary inputs ....................9 Binary outputs....................7 Communications..................24 Features ......................3 Occupancy modes ..................34 Specifications....................6 Supported products..................2 Analog input 01 ....................16 Analog input 02 ....................
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Index Binary input 12 ....................15 Binary inputs Configuration..................11, 57 Descriptions ....................9 List ....................... 29 Occupancy input..................13 Run/stop input .................... 12 Binary output 01 ....................45 Binary outputs Configuration....................10 Descriptions ....................7 List ....................... 29 Output overrides ..................10 Status LED ....................
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Index Cooling source configuration ................56 Damper ........................57 Configuration ....................57 Face and bypass damper operation............47 Operation..................... 50 Outdoor air damper operation ..............48 Troubleshooting..................72, 73 Daytime warmup ..................31, 52 Applications ....................61 Configuration ....................58 Device addressing ....................
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Index Economizing ......................49 Cooling requirements ................31 Effective setpoints ..................21, 33 Electric heat Operation ....................51 Emergency override ................... 53 Exhaust fan Configuration....................57 Operation ....................50 Status ......................15 External setpoint adjustment ................. 32 Face and bypass damper Heat modulation..................
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Index Hardwired setpoint (IN 2) .................20 Heat/cool changeover ..................41 Heating mode ...................39, 42, 44 Heating source configuration ................56 Inputs required for unit operation ..............67 Inputs/outputs Ratings.......................7, 8 Summary..................... 29 Internal setpoint adjustment ................32 Local setpoint .......................17 Enable or disable ..................21 Location identifier ....................
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Index Effect on face and bypass damper operation........47, 59 Freeze avoidance .................. 53, 59 Output overrides ....................10 Using Tracer Summmit or Rover............... 53 Peer-to-peer communication ..............24, 62 Power connections ..................... 28 Power requirements .....................6 Power up sequence ....................31 Red Service LED activity ...................
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Index Measuring using a zone sensor ............16, 20 Setpoint configuration ................58 Setpoint operation ..................32 Setpoint selection..................32 Timed override requests................16 Space Temperature Failure diagnostic ............16 Standalone operation ..................61 Occupancy input..................13 Peer-to-peer communication..............62 Status LED ......................
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Index Valves Modulating valves ..................46 Operation..................... 46 Steam valve cycling................47, 60 Troubleshooting..................71, 72 Water valve override .................. 54 Variable air volume Control ....................30, 45 Fan operation ....................46 Morning warmup control ................51 Operation based on effective heat/cool output........76 .........................
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La Crosse For more information contact your local sales office or Since The Trane Company has a policy of continuous product and product data improvement, e-mail us at comfort@trane.com it reserves the right to change design and specifications without notice.