Trane IntelliPak Operating instructions

April 2010 RT-SVP04F-EN

Programming

Troubleshooting

Guide

IntelliPak™ I and II

Commercial Single Zone Rooftop Air

Conditioner with Variable Air Volume (VAV)

Controls

Model Number

IntelliPak I models S*HF*20-75, S*HL*20-75, S*HG*90-130, S*HK*90-130 Ton

W*HB, W*HE

IntelliPak II models S*HJ090-162, W*HCA-C

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Commonly Used Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

UCM Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Human Interface Module (Local = 1U2, Remote = 9U13 IntelliPak II) (1U65 IntelliPak I)

Unit Operation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Password Protected Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

System Operating Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

STATUS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

System Programming SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

SETUP Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Ventilation Override Definitions (with VOM installed) . . . . . . . . . . . . . . . . . . 66

Temperature Input Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

System Programming SETPOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

SETPOINT Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

CONFIGURATION Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

System Testing & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

SERVICE MODE Menu (Local Human Interface only) . . . . . . . . . . . . . . . . . . . 108

DIAGNOSTICS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Failure Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Communication Link Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Contents

RT-SVP04F-EN 3

Commonly Used Acronyms

For convenience, a number of acronyms and abbreviations are used throughout this

manual. These acronyms are alphabetically listed and defined below.

General Information

Ta b l e 1. A c r o n y m s

Act = active HGBP = Hot Gas Bypass

AH = Air Handler HGP = Hot Gas Bypass

Annunc = Annunciator Hi = high

AS = AirSide HI = where all caps Human Interface

Aux = auxiliary HO = History Only (Diagnostic)

BAS = building automation systems HVAC = heating, ventilation and air conditioning

BCI = BACnet®Communication Interface ICS = Integrated Comfort System

CCFM = hundreds of cubic-feet-per-minute IGV = inlet guide vanes

CCW = counterclockwise INFO = Information Only (Diagnostic)

cfm = cubic-feet-per-minute I/O = input/output

Cfg = Configured, configuration Indep = Independent

ckt = circuit IOM = installation/operation/ maintenance manual

Cmd = command IPC = interprocessor communications

Comp (s) = compressor, compressors IPCB = interprocessor communications bridge (module)

Cond = condenser, condensers IWC = inches water column

Config = configured, configuration LH = left-hand

Ctrl = control Lo = low

CV = constant volume LCI = LonTalk®Communication Interface

Cy = cycle LCI-I = LonTalk Communication Interface for IntelliPak

Module

CVDA = Constant Speed Fan (CV)/Discharge Air Temp Control Manif = manifolded

CVZT = Constant Speed Fan (CV)/Zone Temperature Control Max = maximum

CW = clockwise Min = minimum

DCV = Demand Control Ventilation Misc = miscellaneous

Dflt = default MCM = Multiple Compressor Module

Diag = diagnostic MDM = Modulating Dehumidification Module

Dmpr = damper Mod = modulating

DWU = Daytime Warm-up MPM = Multi-Purpose Module

E/A = exhaust air MWU = morning warm-up

ECEM = exhaust control/enthalpy module NSB = night setback panel

Econ = economizer, economizing Num = number

Ent = entering O/A = outside air

Evap = evaporator Occ = occupied

F/A = fresh air OVRD = override

Funct = function PAR = Partial System Disable, Auto Reset (Diagnostic)

GBAS = generic building automation system (module) PMR = Partial System Disable, Manual Reset (Diagnostic)

Pos = position

4RT-SVP04F-EN

General Information

Note: Echelon, LON, LONWORKS, LonBuilder, NodeBuilder, LonManager, LonTalk,

LonUsers, Neuron, 3120, 3150, the Echelon logo, and the LonUsers logo are

trademarks of Echelon Corporation registered in the United States and other

countries. LonLink, LonResponse, LonSupport, LonMaker, and LonPoint are

trademarks of Echelon Corporation.

Note: BACnet® is a registered trademark of the American Society of Heating,

Refrigeration and Air-conditioning Engineers Inc. (ASHRAE.)

Glossary of Terms

Carefully review these definitions since they are used throughout this document and

the Installation, Operation, Maintenance Guide (IOM). Knowledge of these terms is

essential in gaining an understanding of how these units operate.

Active SETPOINT. The SETPOINT which is currently being used for control by the

SETPOINT source selection.

BACnet®.An open, device networking communications protocol for controls. This

protocol utilizes BACnet and ANSI/ASHRAE Standard 135-2004 protocol which provides

building owners the capability to connect various types of building control systems or

subsystems together.

Pot = potentiometer SZ = single-zone (unit airflow)

PPM = parts per million TCI = Tracer communications interface (module)

HEAT = where all caps HEAT (module) Press = pressure

Propor = proportional Temp = temperature

psig = pounds-per-square-inch gauge pressure UCM = Unit Control (Module)

PWS = part-winding start Unocc = unoccupied

R/A = return air VAV = variable air volume

Refrig = refrigerant VCM = ventilation control module

RH = right-hand VDC = volts DC

RHI = Remote Human Interface Ventil = ventilation

rpm = revolutions-per-minute VFD = variable frequency drive

RT = rooftop unit VOM = ventilation override module

RTM = rooftop module VVDA=Variable Speed Fan (VAV)/Discharge Air Temp Control

SA = supply air W/ = with

SAP = supply air pressure w.c. = water column

Sat = saturated WU = warmup

SCM = Single Compressor Module XL = across-the-line start

Setpt = SETPOINT

SF = supply fan

SRC = source

Stg = stage

Stnd = standard

STP = SETPOINT

Sw = switch

RT-SVP04F-EN 5

General Information

Comparative Enthalpy. An economizer control strategy which compares return air

enthalpy with outdoor enthalpy. The air with the least heat content (enthalpy) is used

for cooling.

Compressor Protection Switch. A pressure switch installed on the suction line that

prevents compressor operation below the switch’s SETPOINT. The purpose is to prevent

no-flow scroll compressor operation.

Comm3/4. Trane proprietary network communication protocol.

Comm5. Trane's implementation of LonTalk or BACnet (an open network

communication protocol).

Condenser Pressure. The saturated condenser pressure measured on each circuit's(2)

condenser section on Evaporative Condenser units. Condenser pressure is converted

to Saturated Condenser Temperature for display on the Human Interface. The data

from these sensors is used in head pressure control.

Control Band. The range of temperatures or pressures which would normally be

maintained by the various control functions.

Control Point. The value of a SETPOINT that an algorithm is using at any given time.

Deadband. As applied to SA temp control, this refers to a range of temperatures

equally spaced above and below the SA temp control point in which the control

algorithm is satisfied.

Dehumidification Override High Zone Temp. The temperature in the critical zone on

VAV units where Dehumidification is disabled to prevent over-heating the space due to

excess reheat.

Dehumidification Override Low Zone Temp. The temperature in the critical zone on

VAV units where Dehumidification is disabled to prevent sub-cooling the space due to

insufficient reheat.

Demand Control Ventilation (DCV). An ASHRAE compliant ventilation scheme that

varies the Outside Air Damper minimum position or Fresh Air Flow (TRAQs) between

minimum and maximum ventilation SETPOINTs based on CO2level.

Dry Bulb. An outdoor temperature above which economizing will be disabled (unless

comparative enthalpy is the economizer control type being used.)

Economizer Zone Temp SETPOINT Suppression. a parameter used for setting the Zone

Temp SETPOINT at a lower value than the mechanical cooling zone temp SETPOINT.

Emergency Stop. A binary input on the RTM which allows unit shutdown with manual

reset when connected to a field-supplied switch.

Energy Recovery Wheel. A device incorporating a specially coated rotating disc that

spins across both outdoor and exhaust air streams transferring to or removing energy

from the incoming outdoor air prior to mixing with return air to increase unit efficiency.

6RT-SVP04F-EN

General Information

Evap Diff. Evap Diff is a calculated value indicating performance of a refrigeration

system. It is calculated by determining the difference between the Entering and Leaving

temperatures of the evaporator. If this value rises too high it may indicate a problem

with the system.

External Stop. A binary input on the RTM that allows unit shutdown, with automatic

reset, when connected to a field-supplied switch.

Hot Gas Bypass. A feature to reduce a refrigeration circuit's cooling capacity by

bypassing hot discharge line refrigerant directly to the evaporator coil of the system to

more effectively operate in low load conditions.

Humidification Control. During modes of continuous fan operation a relay is energized

when the Humidity measured in the controlled space drops below an adjustable

Humidification SETPOINT. The humidifier device is a user supplied device placed in the

supply air stream.

LonTalk. An open, device networking communications protocol for controls. This

protocol is defined in ANSI approved standard EIA/CEA-709.1-A-1999.

Low Ambient Compressor Lockout. A function which prevents compressor operation

at low outdoor ambient temperatures.

Night SetBack (NSB). Applies to the control of the rooftop unit during unoccupied

periods. Also refers to the NSB panel, a communicating wall sensor with night setback

capability.

Reference Enthalpy. An outdoor enthalpy value above which economizing will be

disabled.

Remote Human Interface. A human interface module designed to be mounted

remotely from the unit. There are some functional differences between a unit mounted

and a remote mounted human interface module.

Reset Amount Maximum. The maximum amount of reset allowed.

Reset End Temperature. The temperature at which the maximum reset amount will

occur.

Reset Start Temperature. The temperature at which reset will begin.

Return Fan Control. Return Fan Control is a feature which allows units to operate at a

higher external or duct system static pressure, or to reduce the load (horsepower

requirement) on the supply fan motor. The fan is placed in the return air path.

Return Fan Plenum Pressure. The area between the Exhaust and Return Dampers and

the outlet of the Return Fan defines the return plenum. The absolute static pressure

measured in this area is the Return Fan Plenum Pressure.

RT-SVP04F-EN 7

General Information

Return Plenum Pressure High Limit. This control feature, available on all return fan

options, shuts the supply fan and return fan off if the pressure in the return plenum

exceeds a non-adjustable SETPOINT of 3.5 iwc.

Space Pressure. The pressure in the building as measured by the Space Pressure

Transducer, referenced to outside (atmospheric) pressure.

Supply Air Pressure High Limit. A pressure limit to prevent unit casing and/or ductwork

over pressurization.

Statitrac™. A trademark for control of space pressurization.

Supply Air Pressure. The pressure in inches water column (IWC) of the supply duct

plenum or outlet as measured by the Supply Air Pressure Transducer, referenced to

local outside (atmospheric) pressure.

Supply Air Tempering. Turning on heat when the supply air temperature drops below a

preset value usually due to cold outside air being brought in to provide building

ventilation.

Supply Air Temperature Control Point. The revised value of supply air temperature

SETPOINT after supply air temp reset has been applied.

Supply Air Temperature Reset. A function that shifts the SA Temp SETPOINT an

amount based on the value of another parameter—typically Zone Temp or Outdoor Air

Temp. The purpose of this function is to lower unit capacity to better meet load

requirements.

Ta r g e t . Dynamic control point the unit is controlling to at any given time.

UCM Control System

Trane Large Commercial Rooftop Units are controlled by a microelectronic control

system that consists of a network of modules and are referred to as Unit Control

Modules (UCM).

The unit size, type (CV or VAV), heating functions, peripheral devices, options, exhaust

capabilities, etc. determine the number and type of modules that a particular rooftop

unit may employ.

The UCM receives analog and binary inputs, then processes this information and

supplies outputs in the form of modulating voltages, contact closures, etc. to control

damper actuators, fan motors, compressors, valves, electric heating coils and other

electrical devices in the unit to maintain set comfort levels.

The UCM provides some equipment protection functions both directly and indirectly,

such as duct pressure limits and compressor lockouts.

Listed below are the various modules that may be employed in a UCM control system.

8RT-SVP04F-EN

General Information

Rooftop Module (1U1 IntelliPak II) (1U48 IntelliPak I)

(Standard on all units) The RTM is the central processor of the system. It continuously

receives information from the other unit modules, sensors, the remote control panel,

and customer supplied relays. It then interprets this information and responds to

cooling, heating, and ventilation requests by directing the other modules in the system

to energize the proper unit components. It also directly initiates supply and exhaust fan

operations, and economizer operation.

Compressor Module (SCM/MCM) (IU3 IntelliPak II) (1U49 IntelliPak I)

The Compressor module, (Single Circuit & Multiple Circuit), upon receiving a request

for mechanical cooling, energizes the appropriate compressors and condenser fans. It

monitors the compressor operation through feedback information it receives from

various protection devices.

Heat Module (1U6 IntelliPak II) (1U50 IntelliPak I)

(Standard on all heating units) The Heat module directs the unit’s heater to stage up and

down to bring the temperature in the controlled space to within the applicable heating

SETPOINT.

Exhaust/Comparative Enthalpy Module (1U5 IntelliPak II) (1U52 IntelliPak I)

(Option - used with Statitrac and/or comparative enthalpy) The ECEM receives data

from the return air humidity sensor, the return air temperature sensor, and the return air

space pressure transducer to control the economizer, exhaust fan and the exhaust

dampers to maintain set space pressure.

Ventilation Control Module (7U14 IntelliPak II) (3U218 IntelliPak I)

(Option - used with TRAQ dampers, DCV, and Outdoor Air Preheat) The VCM receives

data from two velocity pressure sensors associated with front and back TRAQ

assemblies to measure fresh air flow entering the unit. These measurements are

converted to CFM and added to give total fresh air flow. This value can be used for

monitoring purposes, to maintain flow to a minimum fresh air flow SETPOINT, or to

maintain appropriate CO2levels in the controlled space using its space CO2sensor

input and the DCV feature. Without TRAQ assemblies installed the VCM can use DCV

and the CO2sensor input to control OA Damper minimum position to maintain CO2

levels in the space. A preheat control relay output is also provided on this module to

maintain tempered outdoor air during ventilation using the VCM Auxiliary Temperature

input. The preheat unit is user-supplied.

Multi Purpose Module (1U9 IntelliPak II) (1U105 IntelliPak I) (Optional - used

with Return Fan Control)

The MPM supports the function of return plenum pressure control by providing inputs

for measuring return plenum pressure, calibrating that reading, and providing an

output to control the return fan speed (if variable speed configured) in response to

control algorithm requests.

RT-SVP04F-EN 9

General Information

Modulating Dehumidification Module (1U15 IntelliPak II) (1U107 IntelliPak I)

(Optional - used with Dehumidification Control)

The MDM supports specific control inputs and outputs for Modulating Dehumidification

control including modulating Reheat and Cooling valve control as well as the Reheat

Pumpout Coil Relay output.

Generic Building Automation System Module (1U10 = GBAS 0-5V, 1U11 = GBAS

0-10V IntelliPak II) (1U51 = GBAS 0-5V/0-10V IntelliPak I) (Optional - used with

Non-Trane Building Control System)

The Generic Building Automation System (GBAS) module allows a non-Trane building

control system to communicate with the unit and accepts external SETPOINTs in form

of analog inputs (0 - 5 V or 0 - 10 V depending on the module selected) and a binary

Input for demand limit. Five (5) binary outputs are available on 0 - 5 V modules. One (1)

binary output and four (4) analog outputs are available on the 0 - 10 V modules. Refer to

the “Field Installed Control Wiring” section of the Unit Installation, Operation,

Maintenance Manual (IOM) for the control wiring to the GBAS module and the various

desired SETPOINTs with the corresponding DC voltage inputs.

Ventilation Override Module (VOM) (1U8 IntelliPak II) (1U53 IntelliPak I)

(Optional - used on units with special ventilation requirements)

The Ventilation Override module can control the unit’s air handling functions to perform

customer specified functions such as space pressurization, exhaust, purge, unit off, etc.

Interprocessor Communications Board (IPCB) (1U12 IntelliPak II) (1U55

IntelliPak I) (Optional - used with Optional Remote Human Interface)

The Interprocessor Communication Board expands communications from the unit UCM

network to a Remote Human Interface Panel. DIP switch settings on the IPCB module for

this application should be; Switches 1 and 2 “Off”, Switch 3 “On”.

BACnet Communication Interface Module (BCI) (1U66 IntelliPak II) (1U104

IntelliPak I) (Optional - used on units with Trane ICS or 3rd party Building

Automation Systems)

The BACnet Communication Interface module expands communications from the unit

UCM network to a Trane Tracer Summit, or a 3rd party building automation system that

utilizes BACnet, and allows external SETPOINT and configuration adjustment and

monitoring of status and diagnostics.

Lontalk Communication Interface Module (LCI) (1U7 IntelliPak II) (1U65

IntelliPak I) (Optional - used on units with Trane ICS or 3rd party Building

Automation Systems)

The LonTalk Communication Interface module expands communications from the unit

UCM network to a Trane Tracer Summit, or a 3rd party building automation system that

utilizes LonTalk, and allows external SETPOINT and configuration adjustment and

monitoring of status and diagnostics.

10 RT-SVP04F-EN

General Information

Human Interface Module (Local = 1U2, Remote = 9U13 IntelliPak II) (1U65 IntelliPak I)

The Human Interface (HI) Module illustrated in Figure 1 is the device which enables the

customer, building owner, or contractor, to communicate to the Rooftop unit the

necessary parameters for unit operation such as cooling and heating SETPOINTs,

demand limiting, ventilation override modes, etc.

The local (unit mounted) Human Interface and the Remote Human Interface Panel

functions are identical, except for Service mode which is not available on the Remote

Human Interface Panel.

The local HI Module is located in the unit’s main control panel. A small door located in

the unit’s control panel door allows access to the HI Module’s keypad and display

window.

There is a 2 line by 40 character LCD screen which provides status information for the

various unit functions as well as menus used to set or modify the operating parameters.

There is a 16 key keypad adjacent to the LCD screen, which allows the operator to scroll

through the various menus and make adjustments to the SETPOINTs, etc.

The information displayed in the LCD window will be top-level status information

unless the operator initiates other displays.

At power-up, the Human Interface LCD will display one of four initial screens illustrated

in the “General Status” section.

1. Unit Status (Unit Off or Stopped) (The unit is configured and operational, but is not

running). This screen shows state, mode, and function information when the unit is

off or stopped.

2. Unit Status (Unit On) (The unit is configured and operational, and is running). This

screen shows state, mode, and function information when the unit is on.

3. VOM Active (a ventilation override command was received) This screen shows that

the unit is in a Ventilation Override Mode.

4. No Configuration (the unit needs to be configured). This screen shows that required

configuration data is missing.

The LCD screen has a backlight that makes the information easier to read. The light will

go out if no keys are pressed for 30 minutes. If it goes out, simply press the STATUS

key.

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