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

RT-SVP04F-EN © 2010 Trane All rights reserved
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)
10
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.