Trane Tracker Version 12 Manual

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BMTK-SVN01D-EN
Hardware Installation
Tracker™Version 12
Building Automation System

Hardware Installation
Tracker™Version 12
Building Automation System
BMTK-SVN01D-EN
February 2004
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BMTK-SVN01D-EN
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Tracker Version 12 Building Automation System Hardware Installation
This guide and the information in it are the property of American Standard Inc. and may not be used or reproduced in whole or in part,
without the written permission of American Standard Inc. Since Trane has a policy of continuous product improvement, it reserves the
right to change design and specification without notice.
Use of the software contained in this package is provided under a software license agreement. Unauthorized use of the software or
related materials discussed in this guide can result in civil damages and criminal penalties. The terms of this license are included with
the compact disk. Please read them thoroughly.
Although Trane has tested the hardware and software described in this guide, no guarantee is offered that the hardware and software
are error free.
Trane reserves the right to revise this publication at any time and to make changes to its content without obligation to notify any per-
son of such revision or change.
Trane may have patents or patent applications covering items in this publication. By providing this document, Trane does not imply
giving license to these patents.
The following are trademarks or registered trademarks of Trane: Tracer, Tracker, Trane, Precedent, Rover, VariTrac, Vari-
Trane, and Voyager.
The following are trademarks or registered trademarks of their respective companies or organizations: LonMark, LonTalk,
and Neuron from Echelon Corporation; ReliaTel from Tone Software Corporation.
Printed in the U.S.A.
© 2004 American Standard Inc. All rights reserved.
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™®

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BMTK-SVN01D-EN
NOTICE:
Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully:
WARNING
Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.
CAUTION
Indicates a situation that may result in equipment or property-damage-only accidents.
The following format and symbol conventions appear at appropriate sections throughout this manual:
IMPORTANT
Alerts installer, servicer, or operator to potential actions that could cause the product or system to
operate improperly but will not likely result in potential for damage.
◆This symbol precedes a procedure that consists of only a single step.
Note:
A note may be used to make the reader aware of useful information, to clarify a point, or to describe
options or alternatives.

BMTK-SVN01D-EN i
Contents
Chapter 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Controller components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Termination module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Main module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Display module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tracker controller specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UCM maximum capacities for Tracker models 12 and 24 . . . . . . . . . . 10
UCM maximum capacities for Tracker model WSHP . . . . . . . . . . . . . . .11
Before installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Verify the shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect for shipping damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Store unused components until needed . . . . . . . . . . . . . . . . . . . . . 12
After installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FCC compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 2 Termination module mounting . . . . . . . . . . . . . . 15
Select a location for the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Verify location conformance to controller specifications . . . . . . . . 15
Verify location conformance to controller dimensions and
clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Verify location conformance to optimal touch screen viewing
angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mount the termination module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Securing the termination module to a wall . . . . . . . . . . . . . . . . . . . 20
Securing the termination module to a conduit box . . . . . . . . . . . . 20
Installing electrical conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 3 Termination board wiring . . . . . . . . . . . . . . . . . . . 23
Wire 24 Vac power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wire optional inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wire the alarm relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Wire the priority shutdown device . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Wire the utility pulse meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Wire the thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Contents
ii BMTK-SVN01D-EN
Wire the UCMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Wire specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
UCM wiring configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Termination resistor placement for Comm5 links . . . . . . . . . . . . . . 34
Wire supported UCMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Requirements for repeaters on Comm5 communication links . . . 37
Chapter 4 Main module mounting . . . . . . . . . . . . . . . . . . . . 41
Chapter 5 Display module mounting. . . . . . . . . . . . . . . . . . . 43
Chapter 6 PC workstation wiring. . . . . . . . . . . . . . . . . . . . . . 47
Verify PC workstation specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Direct connection to PC workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Modem connection to PC workstation . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ethernet connection to PC workstation . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connecting over an existing LAN . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connecting through a hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Connecting with one cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Troubleshooting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Service pin buttons and jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Symptom/action troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Chapter 8 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cleaning the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Calibrating the touch screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Appendix A Installation checklists . . . . . . . . . . . . . . . . . . . . . . 65
Appendix B Declaration of Conformity. . . . . . . . . . . . . . . . . . . 73
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

BMTK-SVN01D-EN 1
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Chapter 1
Overview
The Tracker building automation system (BAS) is an energy management
system for small- to medium-size buildings. The Tracker BAS controls
heating, ventilating, and air conditioning (HVAC) equipment. It consists
of a Tracker controller (Figure 1) and an optional PC workstation.
The Tracker BAS can be operated by using either a Tracker controller or a
PC workstation that is running Tracker PC Workstation software. A
visual interface enables an operator to set up and change HVAC
operating parameters and to collect and display building information.
The Tracker PC Workstation software allows a PC to be connected to the
Tracker controller directly with a prescribed adapter and cable, locally
over a standard Ethernet local area network (LAN) connection, or
remotely with a modem and standard phone line.
The Tracker BAS supports Comm5 communications architecture, which
is the Trane implementation of LonTalk®protocol. It resides on a network
(Figure 2 on page 2 and Figure 3 on page 3) that includes HVAC and
other comfort-related equipment, such as Trane VariTrac zoning systems;
zoning controls; unit control modules (UCMs), which control and monitor
other HVAC equipment; Tracer LCI-V (LonTalk®communication
interfaces for Voyager rooftop controls); Tracer LCI-R (LonTalk®
communication interfaces for ReliaTel rooftop controls); external input/
output (I/O) devices, which help to monitor and control specific areas or
devices; and miscellaneous equipment such as sensors, lights, and fans.
Figure 1. Tracker controller

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Chapter 1 Overview
2BMTK-SVN01D-EN
Figure 2. Example Tracker building automation system (models 12 and 24) on a network
VariTrac central
control panel
VariTrac or VariTrane
zone dampers
Voyager rooftop
Voyager constant
volume rooftop
Precedent rooftop
with ReliaTel controls
Priority shutdown
contact input
Outdoor air
temperature sensor input
Utility pulse meter input
Tracer ZN517
unitary controller
Interconnecting wiring
(Comm5 link): single, twisted
pair, shielded wire for two-
way communication.
Universal inputs
Binary outputs
Direct, dial-in (modem),
or Ethernet connection
Alarm relay output
Tracker
controller
Generic rooftop
Tracer MP503
I/O module
Analog inputs
Binary outputs
Binary inputs
TCI-V
Tracer
LCI-V
Tracer
LCI-R

Overview
BMTK-SVN01D-EN 3
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Figure 3. Example building automation system (water-source heat pump) on a network
Voyager constant
volume rooftop
Precedent rooftop
with ReliaTel controls
Priority shutdown
contact input
Outdoor air
temperature sensor input
Utility pulse meter input Analog inputs
Binary outputs
Tracer ZN517
unitary controller
Binary inputs
Interconnecting wiring
(Comm5 link): single, twisted
pair, shielded wire for two-
way communication.
Universal inputs
Binary outputs
Alarm relay output
Tracker
controller
Generic rooftop
Tracer MP503
I/O module
Analog inputs
Binary outputs
Binary inputs
Tracer ZN510, ZN511, or
ZN524 controller
Tracer loop controller
(for water-source
pump)heat
Tracer
LCI-V
Tracer
LCI-R
Direct, dial-in (modem),
or Ethernet connection

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Chapter 1 Overview
4BMTK-SVN01D-EN
Controller components
The controller consists of a termination module, main module, and
display module (Figure 4).
Figure 4. Tracker controller components
Termination module
Main module
Display module

Controller components
BMTK-SVN01D-EN 5
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Termination module
The termination module (Figure 5) is a housing that provides a
termination board and cable access for power, communications, and
system input connections. Mounting holes enable it to be mounted on a
wall or a recessed conduit box. The termination board accepts connections
for power, communications, and system inputs.
Figure 5. Termination module
Termination
board
Cable access
(three places)

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Chapter 1 Overview
6BMTK-SVN01D-EN
Main module
The main module (Figure 6) is a housing that contains the main logic
board and the Ethernet board. The main module can be “hot swapped”: it
can be removed and installed without removing power from the
termination module. When the main module is installed onto a powered
termination module, it receives power and begins to operate
automatically.
The main logic board provides an Ethernet LAN port, a PC interface port,
and a modem port. It provides an internal interface to termination
module I/O. It also provides Comm5 communication, 24 VAC power,
alarm, and communication indicators. It communicates and exchanges
data with the devices wired to the termination module. It also
communicates with the display module.
The Ethernet board provides two LED indicators. One shows that an
Ethernet link is detected; the other shows that there is serial traffic
between the Ethernet board and the main logic board.
Figure 6. Main module
Modem port
PC interface port
Ethernet LAN port
Main logic board
Ethernet
board

Controller components
BMTK-SVN01D-EN 7
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Display module
The display module (Figure 7) is a housing that contains a printed circuit
board, liquid crystal display (LCD) touch screen, and an alarm LED. The
printed circuit board supports the LCD touch screen and the alarm LED.
The touch screen provides the operator access to the user interface
program.
The display module can be “hot swapped:” it can be removed and installed
without removing power from the main module. When the display module
is installed onto a powered main module, it receives power and begins to
operate automatically.
Figure 7. Display module
LCD touch screen
Alarm LED

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Chapter 1 Overview
8BMTK-SVN01D-EN
Model numbers
Each controller is identified by a model number that provides information
about the controller (Figure 8).
Figure 8. Model number definition
Digit number 12345678910 11 12 13 14
Model number B M T K 0 0 0 A A 0 A x 1 0
Digit Description
1–2 BM = Building management
3–4 TK = Tracker
5–7 Customer ID:
000 = Customer sales office (CSO)
KBB = Independent wholesale distributor (IWD)
8 A = 24 Vac, 50/60 Hz
9 Ethernet option
A = Modem with no Ethernet LAN option
B = Modem with Ethernet LAN option
10–11 0A = Design sequence
12 Model/software options:
1 = Model 12
2 = Model 24
3 = N/A
4 = N/A
5 = WSHP (water-source heat pump)
6 = N/A
13 Display options:
1 = LCD touch screen
14 Language options:
0 = English

Tracker controller specifications
BMTK-SVN01D-EN 9
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Tracker controller specifications
Table 1 shows the specifications for the Tracker controller.
Table 1. Tracker Controller specifications
Specification Description
Power 24 Vac nominal (19 Vac to 30 Vac),
50/60 Hz, 1 phase 40 VA minimum,
UL Class 2 transformer required
Operating environ-
ment
From 32°F to 122°F (0°C to 50°C)
10% to 90% relative humidity, non-condensing
Storage environment From –40°F to 185°F (–40°C to 85°C)
5% to 95% relative humidity, non-condensing
Cabinet NEMA 1 resin enclosure—plenum rated
Mounting Flat wall surface with one of the following recessed
conduit boxes:
2 in. × 4 in. (5.08 cm × 10.15 cm)
4 in. × 4 in. (10.15 cm × 10.15 cm)
Dimensions Height: 8.75 in. (22.38 cm)
Width: 10.25 in. (26.04 cm)
Depth: 2.75 in. (6.99 cm)
Weight 2.5 lb (1.13 kg)
Analog input
•Thermistor
10 kΩat 77°F (25°C)
From –50°F to 200°F (–46°C to 93°C)
Binary inputs
•Utility pulse meter
•Priority shutdown
User-supplied dry contacts only. Tracker-supplied
voltage of 12 Vdc nominal (10 Vdc to 14 Vdc) at
12 mA nominal (10 mA to 14 mA).
Binary output
•Alarm relay
Tracker-supplied single-pole single-throw (SPST) dry
contact rated at 24 Vac, 0.5 A maximum
Memory backup At power loss, the system backs up memory and
stores all data for seven days. After seven days,
trends and alarms are not retained.
Approvals See Appendix B, Declaration of Conformity.

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Chapter 1 Overview
10 BMTK-SVN01D-EN
UCM maximum capacities for Tracker
models 12 and 24
The Tracker model 12 and 24 controllers can control and monitor specific
types and numbers of Trane unit control modules (UCMs) as specified in
this topic. The supported UCMs are as follows:
•HVAC controllers that conform to the LonMark®Space Comfort Con-
troller (SCC) profile: the primary controller options are the Voyager
rooftop with a Tracer LCI-V, Precedent rooftop with ReliaTel controls
and a Tracer LCI-R, and Tracer ZN517 unitary controller. Other con-
trollers are limited to the Tracer ZN510, ZN511, and ZN524.
•VariTrac central control panels (CCPs) with a TCI-V.
•Tracer MP503 I/O module.
Table 2 shows the maximum number of each UCM type that can be linked
to each Tracker controller model. Any combination of the specified UCMs
may be used in aggregate if they do not exceed the maximum. (For
example: A fully loaded Tracker 24 controller can control 24 SCC devices,
10 VariTrac CCPs, and 4 Tracer MP503 I/O modules.)
The Trane VariTrac CCP is the main controller for either a changeover
bypass system configuration or a delivered variable air volume (VAV)
system configuration. Any combination of CCP configurations may be
used in aggregate, as long as they do not exceed the maximum.
Note:
•Each VariTrac CCP configured for changeover bypass can
control 1 HVAC device and up to 24 VAV UCMs.
•Each VariTrac CCP configured for delivered VAV can con-
trol 1 HVAC device and up to 32 VAV UCMs.
•See repeater information, “Requirements for repeaters on
Comm5 communication links” on page 37.
Table 2. Tracker controller models 12 and 24 UCM capacities
Tr a ck e r m o d e l UCM type Maximum
UCMs
24 SCC* 24
Trane VariTrac CCP 10
Tracer MP503 I/O module 4
To t a l maximum UCMs supported 38
12 SCC* 12
Trane VariTrac CCP 5
Tracer MP503 I/O module 4
To t a l maximum UCMs supported 21
* SCCS supported by Tracker are limited to Voyager rooftops, Precedent rooftops with
ReliaTel controls, Tracer ZN517, ZN510, ZN511, and ZN524.

UCM maximum capacities for Tracker model WSHP
BMTK-SVN01D-EN 11
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UCM maximum capacities for Tracker
model WSHP
The Tracker model WSHP controller can control and monitor specific
types and numbers of Trane unit control modules (UCMs) as specified in
this topic. The supported UCMs are as follows:
•Space Comfort Controllers (SCCs): the primary controller options are
the Tracer ZN510, ZN511, and ZN524. Other controllers are limited
to Voyager rooftops with a Tracer LCI-V, Precedent rooftops with Reli-
aTel controls and a Tracer LCI-R, and Tracer ZN517 unitary control-
lers
•Tracer loop controller (TLC)
•Tracer MP503 I/O module
Table 3 shows the maximum number of each UCM type that can be linked
to each Tracker controller model. Any combination of the specified UCMs
may be used in aggregate if they do not exceed the maximum. (For
example: As the table shows, a fully loaded Tracker WSHP controller can
control 100 SCC devices, 1 Tracer loop controller (TLC), and 4 Tracer
MP503 I/O modules.)
IMPORTANT
SCC compressor operation will be enabled only when a TLC is commu-
nicating with the Tracker panel.
Note:
See repeater information, “Requirements for repeaters on
Comm5 communication links” on page 37.
Table 3. Tracker controller model WSHP UCM capacities
Tr a c ke r m o d e l UCM type Maximum
UCMs
WSHP SCC* 100
TLC** 1
Tracer MP503 I/O module 4
To t a l maximum UCMs supported 105
* SCCS supported by Tracker are limited to Tracer ZN510, ZN511,and ZN524; Voyager
rooftops; Precedent rooftops with ReliaTel controls; and Tracer ZN517.
** The TLC is mandatory and must be present to enable SCC compressor operation.

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Chapter 1 Overview
12 BMTK-SVN01D-EN
Before installation
Before beginning to install the Tracker controller, make sure that you
have all the necessary controller components and that they are
undamaged. Also, take steps to protect components until they are needed.
IMPORTANT
Before you install the Tracker hardware, review this guide and other
Tracker support literature and create an installation plan.
Verify the shipment
When the shipment arrives at the job site, carefully unpack the carton.
Even though outgoing orders are thoroughly reviewed before leaving the
factory, compare the items in the shipment with the shipping
authorization paper and verify that all items are present.
Verify that the controller model received is the model that you ordered
and write down the model number for use later.
Inspect for shipping damage
Inspect the items in the shipment to verify that no shipping damage or
loss occurred. If your inspection reveals damage or material shortage:
•Make the appropriate notation on the carrier delivery receipt.
•Immediately file a claim with the carrier, specifying the extent and
type of damage and/or shortage found.
•Notify the appropriate Trane representative.
Store unused components until needed
CAUTION
Avoid Equipment Damage!
Store all Tracker components off-site until most or all of the building
construction is complete. Failure to do so could result in damage to
components.
The termination module is shipped detached from the main module and
display module assembly. To protect the controller from damage, Trane
recommends storing the main module and display module assembly away
from the construction and/or installation site to prevent it from being
damaged or lost. Verify that the storage site conforms to the specifications
shown in Table 1 on page 9.
Note:
Contact your sales office to order additional Tracker literature,
if needed.