Manual Trane ZN521

Installation and
Operation
Tracer ZN521 Zone Controller
SAFETY WARNING
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing
of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and
training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or
serious injury. When working on the equipment, observe all precautions in the literature and on the tags,
stickers, and labels that are attached to the equipment.
November 2010
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Copyright
2010 Trane
All rights reserved
This document and the information in it are the property of Trane and may not be used
or reproduced in whole or in part, without the written permission of Trane. Trane reserves
the right to revise this publication at any time and to make changes to its content without
obligation to notify any person of such revision or change.
Trademarks
Trane and its logo are trademarks of Trane in the United States and other countries. All
trademarks referenced in this document are the trademarks of their respective owners.
Warnings, Cautions, and Notices

Warnings, cautions, and notices are provided in appropriate places throughout this
document:
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,

could result in minor or moderate injury. It could also be used to alert against
unsafe practices.
NOTICE: Indicates a situation that could result in equipment or propertydamage-only accidents.
Doc Number (Variable)
Table of Contents
Overview and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Storage environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Agency listing/compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General wiring information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Input/output terminal wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AC power wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Communication-link wiring and addressing . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mounting the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Location recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operating environment requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mounting recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Input/output functions and wiring for typical applications . . . . . . . . . . . . . . . . . 13

Binary inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BI1: Low-coil-temperature detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BI2: Condensate overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BI3: Occupancy or generic binary input . . . . . . . . . . . . . . . . . . . . . . . . . .
BI4: Fan status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
14
14
Analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
GND: Ground terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZN: Zone temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SET: Local setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN: Fan mode input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AI1: Entering water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AI2: Discharge air temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AI3: Outdoor air temperature or generic temperature . . . . . . . . . . . . . . .
AI4: Universal 420 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
15
15
16
16
16
17
Binary outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Generic binary output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overriding binary outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wiring requirements and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Sequence of operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power-up sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Random start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Occupancy modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Occupied mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Unoccupied mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Occupied standby mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Occupied bypass mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Timed override control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Zone temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cascade zone control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Simplified zone control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Discharge air tempering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Morning warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Morning cool-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Heating or cooling mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Entering water temperature sampling function . . . . . . . . . . . . . . . . . . . . . . . 35
Fan operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Exhaust control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Modulating valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modulating valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two-position valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Isolation-valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two-pipe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four-pipe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
36
36
37
37
Modulating outdoor/return air dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ASHRAE Cycle 1 conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ASHRAE Cycle 2 conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Economizing (free cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Two-position control of a modulating outdoor air damper . . . . . . . . . . . . . 39

Face-and-bypass damper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Face-and-bypass, isolation-valve operation . . . . . . . . . . . . . . . . . . . . . . . 39
DX cooling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electric heat operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Baseboard heat operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Peer-to-peer communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Unit protection strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Smart reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low-coil-temperature protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan off delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter-maintenance timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freeze avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freeze protection (discharge air temperature low limit) . . . . . . . . . . . . .
4
41
41
41
41
41
41
41
42
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Status indicators for operation and communication . . . . . . . . . . . . . . . . . . . . . . 43

Test button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Manual output test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Service pin button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Interpreting LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Types of diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table of diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Overview and specifications

This guide provides installation and configuration information for the Tracer ZN521 zone controller,
as well as a description of its operations. The overview includes a product description,
specifications, and descriptions of ancillary products that may be necessary.
Product description
The Tracer ZN521 is an application-specific controller that provides direct-digital zone temperature
control. The controller can operate as a stand-alone device or as part of a building automation
system (BAS). Communication between the controller and a BAS occurs by means of a LonTalk
communication link, which complies with the LonTalk protocol.
The Tracer ZN521 supports the following equipment:
Fan coils
Unit ventilators
Blower coils
The Tracer ZN521 can be configured to control:
Tri-state modulating or two-position valves
Tri-state modulating dampers:

outdoor/return air, and face-and-bypass
DX cooling (single stage)
Electric heat (two stages)
It is designed to be field-installed and is sent from the factory unconfigured. Use the PC-based
Rover service tool to configure the controller for specific applications.
Note: For information about using the Rover service tool, see the current version of the Rover
Installation/Operation/Programming guide (EMTX-SVX01).
Storage environment
If a Tracer ZN521 zone controller is to be stored for a substantial amount of time, store it in an indoor
environment that meets the following requirements:
Temperature: 40 to 185F (40 to 85C)
Relative humidity: 595%, noncondensing
Dimensions
Plastic-cover model dimensions
For complete dimensional drawing, see Figure 1 on page 7.
Height: 5.375 in. (137 mm)
Width: 6.875 in. (175 mm)
Depth: 2 in. (51 mm)
Metal-cover model dimensions

For complete dimensional drawing, see Figure 2 on page 8.
Height: 9.0 in (25 mm)
Width: 10.37in. (263 mm)
Depth: 2.25 in. (58 mm)
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Clearances
Plastic-cover model (see Figure 1 on page 7)
Front: 4.0 in. (102 mm)
Each side: 1.0 in. (25 mm)
Top and bottom: 4.0 in. (102 mm)
Metal-cover model (see Figure 2 on page 8)
Front: 24.0 in. (610 mm)
Each side: 2.0 in. (51 mm)
Top and bottom: 1.0 in. (25 mm)
Figure 1. Plastic-cover model dimensions and clearances

1 in
(25 mm)
4 in
(102 mm)
4 in.
(102 mm)
5.625 in.
(143 mm)
6.31
(160 mm)
4 in
(102 mm)
6.875 in
(175 mm)
5.625 in (143 mm)

1 in
(25 mm)
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2 in. (51 mm)
Figure 2. Metal-cover model dimensions and clearances

1 in.
(25 mm)
1.875 in.
(48 mm)
6.5 in.
(165 mm)
0.28 in.
(7 mm)
9 in.
(229 mm)
9 in.
(229 mm)
7 in.
(178 mm)
2 in.
(51 mm)
2 in.
(51 mm)
24 in.
(610 mm)
10.37 in.
(263 mm)
width with cover
Clearances
Dimensions
1 in.
(25 mm)
1 in.
(25 mm)
2.25in.
(58 mm)
10.25 in.
(260 mm)
width without cover
Agency listing/compliance
CEImmunity: EN 50082-1:1997; EN 50082-2:1995
CEEmissions: EN 50081-1:1992 (CISPR 22) Class B
UL and C-UL 916 listed: Energy management system
UL 94-5V (UL flammability rating for plenum use)
FCC Part 15, Class A
ASHRAE Cycle 1 & Cycle 2 control sequences
Additional components
The Tracer ZN521 zone controller requires the use of additional components for monitoring and
proper control of the associated equipment. The use of specific components depends on the
application. These components are not included with the Tracer ZN521 zone controller.
Power transformer
Use a UL-listed Class 2 power transformer supplying a nominal 24 Vac (1930 Vac) to power both
the Tracer ZN521 zone controller (14 VA) and its associated output devices, including relays and
actuators, to a maximum of 12 VA per output utilized.
Water, duct, and outdoor-air temperature sensors

Temperature sensors must be Trane 10 k (at 25C) thermistors. Entering water and discharge air
inputs may use a sealed temperature sensor (part number 4190 1100).
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Binary input switching devices

Occupancy, condensate overflow, low-coil-temperature, and fan status inputs accept switching
devices that may have normally open or normally closed dry contacts.
Output devices
Output devices connected to the Tracer ZN521 binary outputs cannot exceed 12 VA (0.5 A) current
draw at 24 Vac.
Zone temperature sensors

Table 1 shows the Trane zone temperature sensors that are supported by the Tracer ZN521 zone
controller.
Table 1.
Tracer zone temperature sensor options
Fan
BAS
order
number
Use
High
Med
Low
Timed
override
buttons
Zone
Auto
Off
Setpoint
thumbwheel
Temperature
sensor
On
Cancel
Comm
jack
4190 1087
Any
4190 1088
Any
x
x
4190 1090
Any
4190 1094
Any
4190 1095
Unit
ventilator
4190 1115
Fan coil
4190 1116
Unit
ventilator
4190 1117
Any
x
x
Valve actuators
Valve actuators cannot exceed 12 VA draw at 24 Vac. For two-position valves, use actuators with
on/off action, and with a spring action that returns the valve to normally open or closed (dependent
on the desired default position). For modulating valve control, use tri-state modulating actuators
with or without a spring return, as required by the application.
Damper actuators
Damper actuators cannot exceed 12 VA draw at 24 Vac. For control of outdoor/return air dampers,
use tri-state modulating actuators that incorporate a spring return.
Zone humidity sensor

For measurement of relative humidity (RH), the Tracer ZN521 requires a zone humidity sensor with
a 420 mA output, where 4 mA is 0% RH and 20 mA is 100% RH. The controller provides 20 Vdc to
power the zone humidity sensor.
CO2 sensor
For CO2 measurement, the Tracer ZN521 requires a CO2 sensor with a 420 mA output, where 4 mA
= 0 ppm and 20 mA = 2000 ppm.
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General wiring information

This chapter provides specifications and general information about wiring the Tracer ZN521 zone
controller. The controller requires wiring for:
Input/output terminals
AC power to the controller
Communication-link wiring, if the controller is to communicate with a building automation

system (BAS)
Input/output terminal wiring

All input/output terminal wiring for the Tracer ZN521 zone controller is application specific and
dependant on the configuration of the controller. Input/output terminal wiring must meet the
following requirements:
All wiring must comply with the National Electrical Code and local codes.
Use only 18 AWG, twisted-pair wire with stranded, tinned-copper conductors. (Shielded wire
is recommended.)
Binary input and output wiring must not exceed 1000 ft (300 m).
Analog input wiring must not exceed 300 ft (100 m).
Do not run input/output wires in the same wire bundle with any ac power wires.
For application-specific wiring information and diagrams, see Input/output functions and wiring
for typical applications, p. 13
AC power wiring
WARNING
Hazardous Voltage!
Before making line voltage electrical connections, lock open the supply-power disconnect
switch. Failure to do so may cause death or serious injury.
CAUTION
Proper Grounding Required!
Make sure that the 24 Vac transformer is properly grounded. Failure to do so may result in
personal injury or equipment damage.
Notice:
Avoid damage to the controller!
Complete input/output wiring before applying power to the Tracer ZN521 zone controller.
Failure to do so may cause damage to the controller or power transformer due to inadvertent
connections to power circuits.
Important:
Do not share 24 Vac between controllers.
All wiring must comply with National Electrical Code and local codes.
The ac power connections are in the top left corner of the Tracer ZN521 zone controller (see
Figure 3).
10
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General wiring information
Figure 3. Connecting ac power wires to the controller
H
24 Vac
transformer
The Tracer ZN521 may be powered by an existing transformer integral to the controlled equipment,
provided the transformer has adequate power available and proper grounding is observed. If you
are providing a new transformer for power, use a UL-listed Class 2 power transformer supplying
a nominal 24 Vac (1930 Vac). The transformer must be sized to provide adequate power to both
the Tracer ZN521 zone controller (14 VA) and its associated output devices, including relays and
actuators, to a maximum of 12 VA per output utilized.
Communication-link wiring and addressing

The Tracer ZN521 zone controller communicates with the BAS and with other LonTalk controllers
by means of a LonTalk communication link.
Important:
For important instructions on network wiring, refer to the Tracer Summit Hardware
and Software Installation guide (BMTX-SVN01A-EN).
Wiring for the communication link must meet the following requirements:
All wiring must comply with the National Electrical Code and local codes.
22 AWG Level 4 unshielded communications wire recommended for most Comm5

installations.
Termination resistors are required for wiring LonTalk devices communicating on a network. For
specific information about using termination resistors for LonTalk applications, refer to the
Tracer Summit Hardware and Software Installation guide (BMTX-SVN01A-EN).
Each Tracer ZN521 zone controller has a unique 12-character alphanumeric device address for
communicating on a BAS network. This address, referred to as a Neuron ID, is assigned in the
factory before the product is shipped and cannot be changed. Each controller can be identified by
viewing its unique Neuron ID, which is on a printed label attached to the circuit board of the
controller. Additional adhesive-backed, peel-off Neuron ID labels are tethered to the controller for
placing on mechanical prints or unit location worksheets. The Neuron ID will appear when
communication is established with the Rover service tool or a BAS. An example Neuron ID is 0001-64-1C-2B-00.
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11
Mounting the controller

This chapter gives recommendations and requirements for mounting a Tracer ZN521 zone
controller.
Location recommendations
Trane recommends locating the Tracer ZN521 zone controller:
Near the controlled piece of equipment to reduce wiring costs
Where it is easily accessible for service personnel
Where public access is restricted to minimize the possibility of tampering or vandalism
The controller can often be mounted inside the wiring enclosure of the associated mechanical
equipment.
Operating environment requirements

Operate a Tracer ZN521 zone controller in an indoor environment that meets the following
requirements:
Temperature: from 32F to 140F (from 0C to 60C)
Relative humidity: 595%, noncondensing
Mounting recommendations
Mounting recommendations are as follows:
Notice:
Leave Controller Cover On
Mount the Tracer ZN521 zone controller with the cover on to avoid the possibility of damaging
the circuit board during installation.
Mount the controller in any position, other than with the front of the cover facing downward.
Mount using the two 3/16 in. (4.8 mm) radius mounting holes provided (see Figure 4). Mounting
fasteners are not included.
Attach the controller securely so it can withstand vibrations of associated HVAC equipment.
When the controller is mounted in a small enclosed compartment, complete all wiring
connections before securing the controller in the compartment.
Figure 4. Mounting the Tracer ZN521 zone controller
12
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Input/output functions and wiring for typical

applications
This chapter provides information about the function of inputs and outputs and examples of wiring
for typical applications. Applications supported by the Tracer ZN521 zone controller are shown in
Table 2.
2-pipe hydronic cooling only
2-pipe hydronic heating only
2-pipe changeover
2-pipe steam only
4-pipe hydronic heating and cooling
4-pipe changeover
4-pipe steam/chilled water
Electric heat only (single- and two-stage)

DX/hydronic heating
DX/steam heating
DX cooling only
Electric heat
Auxiliary (baseboard) heat
Economizing
Valve control
Auto minimum
damper adjust
Dehumidification
Application
Face and bypass damper
Typical applications for the Tracer ZN521 zone controller
Multiple fan speed
Table 2.
x
x
Figures Step 7 through Step 17 (pages 20 through 30) show typical wiring diagrams that include
all required and all optional components for typical applications.
Binary inputs
The Tracer ZN521 controller includes four binary inputs. Each binary input associates an input
signal of 0 Vac with open contacts and 24 Vac with closed contacts. You can use the Rover service
tool to configure each of the inputs as normally open or normally closed. If an application does not
warrant the use of a particular input, configure the input as Not Used. This will disable the
generation of diagnostics for this function.
Table 3 gives the function of each binary input.
Table 3.
Binary inputs
Binary input
terminal label
CNT-SVX07D-EN
Function
BI1
Low-coil-temperature detection
BI2
Condensate overflow
13
Input/output functions and wiring for typical applications
Table 3.
Binary inputs (continued)
Binary input
terminal label
Function
BI3
Occupancy or generic binary input
BI4
Fan status
Each function is explained in the following paragraphs. For an explanation of the diagnostics
generated by each binary input, see Diagnostics, p. 48. For more information about how the
controller operates, see Sequence of operations, p. 31
BI1: Low-coil-temperature detection

Note: BI1 applies to hydronic/steam coils only.
The function of low-coil-temperature detection is to protect the coil from freezing. If BI1 is wired
to a binary low-coil-temperature detection device (freeze-protection switch) and a low-coiltemperature condition exists, the Tracer ZN521 will detect the condition and generate a Low Coil
Temp Detection diagnostic.
BI2: Condensate overflow

The function of condensate overflow is to prevent the condensate drain pan from overflowing and
causing water damage to the building. If BI2 is wired to a condensate overflow switch and the level
of condensate reaches the trip point, the Tracer ZN521 will detect the condition and generate a
Condensate Overflow diagnostic.
BI3: Occupancy or generic binary input

The BI3 binary input can function as either:
The occupancy input
A generic binary input
The function of occupancy is to save energy by spreading zone setpoints when the zone is
unoccupied. As the occupancy input, BI3 can be used for two related functions. For stand-alone
controllers, BI3 can be hard-wired to a binary switch or timeclock to determine the occupancy
modeeither occupied or unoccupied. For controllers receiving a BAS-communicated occupancy
request, the function of BI3 is to change the mode from occupied to occupied standby. (For more
information on occupancy-related functions, see Occupancy modes, p. 31.)
BI3 is the only binary input that can be configured as generic. If configured as a generic binary input,
it can be monitored by a BAS and has no direct effect on Tracer ZN521 operation.
BI4: Fan status

The fan status input provides feedback to the controller regarding the fans operating status. If BI4
is wired to a fan status switch and the input indicates that the fan is not operating when the
controller has the fan controlled to on, the controller will generate a Low AirFlowFan Failure
diagnostic. (For more information, see Fan status, p. 41.)
Analog inputs
The Tracer ZN521 controller includes seven analog inputs. Table 4 describes their functions. Each
function is explained in the following paragraphs. For an explanation of the diagnostics generated
14
CNT-SVX07D-EN
by each analog input, see Diagnostics, p. 48. For more information about how the controller
operates, see Sequence of operations, p. 31
Table 4.
Analog inputs
Analog input
terminal label
ZN
Function
Zone temperature
GND
Zone sensor common ground
SET
Local setpoint
FAN
Fan mode input
GND
Auxiliary ground
AI1
Entering water temperature
AI2
Discharge air temperature
AI3
Outdoor air temperature or generic temperature
AI4
Universal 420 mA
GND: Ground terminals

Use a GND terminal as the common ground for all zone sensor analog inputs.
ZN: Zone temperature

The ZN analog input functions as the local (hard-wired) zone temperature input. The controller
receives the temperature as a resistance signal from a 10 k thermistor in a standard Trane zone
sensor wired to analog input ZN. A zone temperature value communicated by means of a LonTalk
link can also be used for controllers operating on a BAS. When both a hard-wired and
communicated zone temperature value is present, the controller uses the communicated value. If
neither a hard-wired nor a communicated zone temperature value is present, the controller
generates a Zone Temp Failure diagnostic.
The ZN analog input is also used to communicate timed override requests and cancel requests to
the controller for applications using a Trane zone sensor with ON and CANCEL buttons.
SET: Local setpoint

The SET analog input functions as the local (hard-wired) temperature setpoint input for
applications utilizing a Trane zone sensor with a temperature setpoint thumbwheel. The local
setpoint input is configurable (as enabled or disabled) using the Rover service tool. A setpoint value
communicated by means of a LonTalk link can also be used for controllers operating on a BAS. If
both hard-wired and communicated setpoint values are present, the controller uses the
communicated value. If neither a hard-wired nor a communicated setpoint value is present, the
controller uses the stored default setpoints (configurable using the Rover service tool). If a valid
hard-wired or communicated setpoint value is established and then is no longer present, the
controller generates a Setpoint Failure diagnostic.
FAN: Fan mode input

The FAN analog input functions as the local (hard-wired) fan mode switch input for applications
using the Trane zone sensor with a fan mode switch option. The various fan mode switch positions
(off, low, medium, high, auto) provide different resistances that are interpreted by the Tracer ZN521.
The local fan mode switch input is configurable (as enabled or disabled) using the Rover service
tool. A communicated fan mode request via the LonTalk communications link can also be used for
controllers operating on a BAS. If both hard-wired and communicated fan mode values are present,
the controller uses the communicated value. If neither a hard-wired nor a communicated fan mode
value is present, the controller recognizes the fan mode value as auto and operates according to
CNT-SVX07D-EN
15
the default configuration. If a valid hard-wired or communicated fan mode value is established and
then is no longer present, the controller generates a Fan Mode Failure diagnostic.
AI1: Entering water temperature

The AI1 analog input functions as the local (hard-wired) entering water temperature input. An
entering water temperature communicated via the LonTalk communications link can also be used
for controllers operating on a BAS. If both hard-wired and communicated entering water
temperature values are present, the controller uses the communicated value. If a valid hard-wired
or communicated entering water temperature value is established and then is no longer present,
the controller generates an Entering Water Temp Failure diagnostic.
For units configured as 2-pipe or 4-pipe changeover units, the entering water temperature is used
to make heating/cooling operation decisions. If neither a hard-wired nor a communicated entering
water temperature value is present on changeover units, the controller will always operate in
heating mode.
For units not configured as changeover units, the entering water temperature value is used for
information and troubleshooting only and does not affect the operation of the controller.
Note: AI1 is not polarity sensitive; you can connect either terminal to either sensor lead.
AI2: Discharge air temperature

The AI2 analog input functions as the local discharge air temperature input.
Important:
The Tracer ZN521 cannot operate without a valid discharge air temperature value.
The controller receives the temperature as a resistance signal from a 10 k thermistor wired to
analog input AI2. The thermistor is typically located downstream from all unit heating and cooling
coils at the unit discharge area.
If a discharge air temperature value is invalid or is not present, the controller generates a Discharge
Air Temp Failure diagnostic and shuts down the equipment. When the thermistor returns to a valid
temperature, the controller automatically allows the equipment to resume normal operation.
AI3: Outdoor air temperature or generic temperature

The AI3 analog input can function as either:
An outdoor air temperature input
A generic temperature input
If AI3 is configured as the local (hard-wired) outdoor air temperature input, the controller receives
the temperature as a resistance signal from a 10 k thermistor wired to analog input AI3. An
outdoor air temperature value communicated by means of a LonTalk link can also be used for
controllers operating on a BAS. If both hard-wired and communicated outdoor air temperature
values are present, the controller uses the communicated value. If a valid hard-wired or
communicated outdoor air temperature value is established and then is no longer present, the
controller generates an Outdoor Air Temp Failure diagnostic.
Economizing (free cooling) is a function whereby outdoor air is used as a source of cooling before
hydronic or DX cooling is used. The Tracer ZN521 uses the outdoor air temperature value to
determine whether economizing is feasible. Economizing is not possible without a valid outdoor
air temperature. (For more information, see Economizing (free cooling), p. 38.)
The outdoor air temperature value is also used for the freeze avoidance function. This function is
used for low-coil-temperature protection when the fan is off. The controller enters the freeze
avoidance mode when the outdoor air temperature is below the freeze avoidance setpoint
(configurable using the Rover service tool). (For more information, see Freeze avoidance, p. 41.)
If AI3 is configured as a generic temperature input, it can be monitored by a BAS. The controller
receives the temperature as a resistance signal from a 10 k thermistor wired to analog input AI3.
16
CNT-SVX07D-EN
The generic temperature input can be used with any Trane 10 k thermistor. The thermistor can be
placed in any location and has no effect on the operation of the controller. The controller will
generate a Generic Temperature Failure diagnostic if the input becomes invalid or goes out of
range.
AI4: Universal 420 mA

The AI4 analog input can be configured in one of the three ways shown in Table 5.
Table 5.
AI4 configuration options and associated measurement ranges

Configuration
Measurement range
Generic 420 mA input
0100% (4 mA=0%; 20 mA=100%)
CO2 measurement
02000 ppm (4 mA=0 ppm; 20 mA=2000 ppm)
Relative humidity (RH) measurement
0100% (4 mA=0% RH; 20 mA=100% RH)
If this input is not needed for an application, configure it as Not Used. This will disable the
generation of diagnostics.
Note: AI4 is polarity sensitive.
For the generic input configuration, a 420 mA sensor must be hard-wired to the AI4 terminal.
(Wiring is dependent on the specific application.) The sensor communicates a value of 0100% to
the BAS. This configuration has no direct effect on Tracer ZN521 operation. If a valid value is
established and then is no longer present, the controller generates a Generic AIP Failure diagnostic.
For the CO2 measurement configuration, a 420 mA sensor must be hard-wired to the AI4 terminal
as shown in Figure 5. The sensor will transmit a 02000 ppm value to the BAS. This configuration
has no direct effect on Tracer ZN521 operation. If a valid value is established and then is no longer
present, the controller generates a CO2 Sensor Failure diagnostic.
Figure 5. AI4 terminal wiring: CO2 measurement
Tracer ZN521
24 Vac
CO2 sensor
(Trane 5010 0828 shown)
24 Vac
GND
Signal
For the RH measurement configuration, either a hard-wired 420 mA zone humidity sensor (see
Figure 2) must provide a value to the controller or a BAS communicates a value to the controller.
The controller uses this value to support the dehumidification function. (For more information, see
Dehumidification, p. 40.) If a valid hard-wired or communicated relative humidity value is
established and then is no longer present, the controller generates a Humidity Input Failure
diagnostic and disables the dehumidification function.
CNT-SVX07D-EN
17
Figure 6.
AI4 terminal wiring: RH measurement
Tracer ZN521
RH sensor
Binary outputs
The ZN521 zone controller supports fan coil, blower coil, and unit ventilator applications that may
include the following components:
Supply fan with up to three speeds
Hydronic cooling and/or heating coils with two-position or tri-state modulating control valve
DX cooling (single stage)
Electric heat (single stage or two stage)
Baseboard heat (single stage)
Tri-state modulating outdoor/return air damper
Tri-state modulating face-and-bypass damper
The Tracer ZN521 controller includes ten binary outputs. Each binary output is a triac with a rating
of 12 VA at 24 Vac. Table 6 describes the function of each output.
Table 6.
Binary output functions
Binary output
1
Fan high
Fan medium
Exhaust fan or damper
Fan low
Modulating cooling/changeover valve, open

Two-position cooling/changeover valve
DX cooling
Modulating cooling/changeover valve, close

Face-and-bypass damper, open to face
Modulating heating valve, open

Two-position heating valve
Electric heat, stage 1
Modulating heating valve, close

Face-and-bypass damper, close (bypass)
Outdoor air damper, open (return air damper, close)
Outdoor air damper, close (return air damper, open)
10
18
Functions
Baseboard heat
Generic
CNT-SVX07D-EN
Generic binary output

Binary output 10 is the only output that can be configured as a generic binary output. When
configured as a generic binary output, it can be controlled only by a BAS, and has no direct effect
on Tracer ZN521 operation.
Overriding binary outputs

The Tracer ZN521 controller includes a manual output test and a water valve override feature. Use
the manual output test to manually control the outputs in a defined sequence. For information, see
Manual output test, p. 43.
The water valve override feature is a procedure used for water balancing. Using the Rover service
tool or a BAS, a user can specify that a Tracer ZN521 override the state of water valves to:
Open all valves
Close all valves
The controller resets itself to normal operation after two hours.
Wiring requirements and options

Table 7 shows required controller inputs for minimal proper operation of all applications.
Table 7.
Required controller inputs for proper operation

Function
Input source
For more information,

see:
24 Vac power
Terminals: GND, 24 V
AC power wiring, p. 10
Zone temperature
Terminals: ZN, GND

or communicated
ZN: Zone temperature,

p. 15
Terminals: AI2
AI2: Discharge air

temperature, p. 16

required only for units with auto
changeover
Terminal: AI1
or communicated
AI1: Entering water

temperature, p. 16
Outdoor air temperature

required only for economizing
Terminals: AI3 or
communicated
AI3: Outdoor air

temperature or generic
temperature, p. 16
Relative humidityrequired only

for dehumidification
Terminals: AI4
AI4: Universal 420 mA,

p. 17
Figure 7, p. 20 through Figure 17, p. 30 show typical applications that include all required and all
optional components.
CNT-SVX07D-EN
19
Figure 7.
Two-pipe hydronic-cooling unit
Fan status (closed=on)*
24 V
Fan, high speed
24 V
Exhaust (or fan, medium speed)
24 V
Fan, low speed
24 V
Cooling valve
24 V
Electric heat, stage 1 (optional)
Occupancy (open=occupied)*
24 V
Condensate overflow (closed=normal)*
24 V
Outdoor air damper actuator
Open
Close
24 Vac H
N
Open
Close
(closed=normal)*
24 V
Generic/baseboard heat
LonTalk
AI4 input: See
Figures Step 5
and Step 6 on
p. 18 for wiring
options
LonTalk
Entering water
temperature
Discharge air
temperature
20
in
out
Outdoor air or
generic temperature
* All binary inputs are configurable.

Connect 24 V to an AC POWER (24V) terminal.
CNT-SVX07D-EN
Figure 8. Two-pipe hydronic-heating unit

24 V
Fan, high speed
24 V
24 V
Fan, low speed
24 V
Heating valve
24 V
Open
Close
24 Vac H
N
Open
Close
(closed=normal)*
24 V
LonTalk
AI4 input: See
Figures Step 5
and Step 6 on
p. 18 for wiring
options
LonTalk
Entering water
temperature
in
out
Outdoor air or generic temperature
Discharge air
temperature

CNT-SVX07D-EN
21
Figure 9. Two-pipe hydronic heating/cooling unit with auto changeover
24 V
Fan, high speed
24 V
24 V
Fan, low speed
24 V
Heating/cooling changeover valve
24 V
24 V
24 V
Open
Close
24 Vac H
N
AI4 input: See

Figures Step 5
and Step 6 on
p. 18 for wiring
options
LonTalk
Entering water
temperature
Open
Close
(closed=normal)*
24 V
LonTalk
in
out
Outdoor air or
generic temperature
Discharge air
temperature

22
CNT-SVX07D-EN
Figure 10. Four-pipe hydronic heating/cooling unit

24 V
Fan, high speed
24 V
24 V
Fan, low speed
24 V
Cooling valve
24 V
Heating valve
24 V
Open
Close
Open
Close
24 Vac H
N
Open
Close
(open=normal)*
24 V
LonTalk
AI4 input: See
Figures Step 5
and Step 6 on
p. 18 for wiring
options
LonTalk
Entering water
temperature
in
out
Outdoor air or
generic temperature
Discharge air
temperature

CNT-SVX07D-EN
23
Figure 11. Four-pipe heating/cooling unit with auto changeover

24 V
Fan, high speed
24 V
24 V
Fan, low speed
24 V
Heating/cooling changeover valve
24 V
Auxiliary heating valve
Open
Close
Open
Close
24 Vac H
N
Open
Close
24 V
(closed=normal)*
24 V
LonTalk
AI4 input: See
Figures Step 5
and Step 6 on
p. 18 for wiring
options
LonTalk
Entering water
temperature
in
out
Outdoor air or
generic temperature
Discharge air
temperature

24
CNT-SVX07D-EN
Figure 12. Two-pipe heating unit with DX cooling

24 V
Fan, high speed
24 V
24 V
Fan, low speed
24 V
DX cooling

24 V
Heating valve
24 V
GND 24V 24V 24V
AC POWER
SERVICE
LED
PIN
BI1
BI2
BI3
BI4
BINARY INPUTS
ZONE SENSOR
ZN GND SET FAN GND
Open
Close
24 Vac H
N
Open
Close
(closed=normal)*
10
COMM5
LED
BINARY OUTPUTS
ANALOG INPUTS
AI1
AI2
AI3
COMM5
+20 AI4 GND
24 V
STATUS
LED
}
AI4 input: See
Figures Step 5
and Step 6 on
p. 18 for wiring
options
1
2
On
Cancel
in
out
3
4
5 LonTalk
6
Entering water
temperature
Discharge air
temperature
CNT-SVX07D-EN
LonTalk
Outdoor air or generic temperature

25
Figure 13. Electric heat unit with DX cooling

24 V
Fan, high speed
24 V
Exhaust
24 V
DX cooling
24 V
24 V
24 V

(closed=normal)*
24 V
Open
Close
24 Vac H
N
GND 24V 24V 24V
AC POWER
SERVICE
LED
PIN
BI1
BI2
BI3
BI4
BINARY INPUTS
ZONE SENSOR
ZN GND SET FAN GND
ANALOG INPUTS
AI1
AI2
AI3
1
On
Cancel
10
COMM5
LED
COMM5
+20 AI4 GND
AI4 input: See

Figures Step 5
and Step 6 on
p. 18 for wiring
options
BINARY OUTPUTS
STATUS
LED
LonTalk
in
out
3
4
5
6
LonTalk
Entering water
temperature
Outdoor air or
generic temperature
Discharge air
temperature

26
CNT-SVX07D-EN
Figure 14. Electric heat unit

24 V
Fan, high speed
24 V
Exhaust
24 V
24 V
24 V

(closed=normal)*
Open
Close
24 Vac H
N
24 V
LonTalk
AI4 input: See
Figures Step 5
and Step 6 on
p. 18 for wiring
options
LonTalk
Entering water
temperature
Discharge air
temperature
CNT-SVX07D-EN
in
out
Outdoor air or
generic temperature

27
Figure 15. Two-pipe heating unit with face-and-bypass damper

24 V
Fan, high speed
24 V
24 V
Fan, low speed
24 V
Face & bypass damper actuator
24 V
Heat isolation valve, open/close
24 V
Open
Close
Open
24 Vac H
N
Close
(closed=normal)*
24 V
LonTalk
AI4 input: See
Figures Step 5
and Step 6 on
p. 18 for wiring
options
LonTalk
Entering water
temperature
in
out
Outdoor air or
generic temperature
Discharge air
temperature

28
CNT-SVX07D-EN
Figure 16. Two-pipe heating/cooling unit with face-and-bypass damper

24 V
Fan, high speed
24 V
24 V
Fan, low speed
24 V
Heating/cooling isolation valve, open/close
Open
24 Vac H
N
Close
(closed=normal)*
Open
Close
24 V
Face-and-bypass damper actuator
24 V
24 V
LonTalk
AI4 input: See
Figures Step 5
and Step 6 on
p. 18 for wiring
options
LonTalk
Entering water
temperature
in
out
Outdoor air or
generic temperature
Discharge air
temperature

CNT-SVX07D-EN
29
Figure 17. Four-pipe heating/cooling unit with face-and-bypass damper

24 V
Fan, high speed
24 V
24 V
Fan, low speed

24 V
Cooling isolation valve, open/close
24 V
Face and bypass damper actuator
24 V
Heating isolation valve, open/close
24 V
Open
Close
Open
24 Vac H
N
Close
(closed=normal)*
24 V
LonTalk
AI4 input: See
Figures Step 5
and Step 6 on
p. 18 for wiring
options
LonTalk
Entering water
temperature
Discharge air
temperature
30
in
out
Outdoor air or
generic temperature

CNT-SVX07D-EN
Sequence of operations
The Tracer ZN521 zone controller will operate to maintain the zone temperature setpoint. This
chapter discusses many of the operational sequences used by the controller to accomplish this
goal.
Power-up sequence
When 24 Vac power is initially applied to the Tracer ZN521 zone controller, the following sequence
occurs:
1. The green status indicator LED turns on (see Interpreting LEDs, p. 47).
2. All outputs are controlled off. All modulating valves and dampers close, and the face-andbypass damper calibrates to bypass (when present).
3. The controller reads all input local values to determine initial values.
4. The random-start timer begins (see Random start, p. 31).
5. If a hard-wired zone-temperature value is not detected, the controller begins to wait for a
communicated value. (This can take several minutes [15-minute default] and occurs
concurrently with the remainder of the power-up sequence.)
6. The random-start timer expires.
7.
The power-up control wait function begins automatically if the configured power-up control
wait time is greater than 0 seconds. When this function is enabled, the controller waits for the
configured amount of time (from 0 to 120 seconds) to allow a communicated occupancy
request to arrive. If a communicated occupancy request arrives, normal operation can begin.
If a communicated occupancy request does not arrive, the controller assumes stand-alone
operation.
8. Normal operation begins assuming no diagnostics have been generated.
Random start
Random start is intended to prevent all units in a building from energizing at the same time. The
random-start timer delays the fan and any heating or cooling start-up from 5 to 30 seconds. If
neither heating nor cooling is initiated, or if fan operation is not required during the delay, the
random-start timer will time-out.
Occupancy modes
Occupancy modes can be controlled by any of the following:
The state of the local (hard-wired) occupancy binary input BI3 (see BI3: Occupancy or generic
binary input, p. 14)
A timed override request from a Trane zone sensor (see Timed override control, p. 32)
A communicated signal from a peer device (see Peer-to-peer communication, p. 40)
A communicated signal from a BAS
A communicated request, either from a BAS or a peer controller, takes precedence over local
requests. If a communicated occupancy request has been established and is no longer present, the
controller reverts to the default (occupied) occupancy mode after 15 minutes (if no hard-wired
occupancy request exists). The Tracer ZN521 has the following occupancy mode options:
CNT-SVX07D-EN
Occupied
Unoccupied
Occupied standby
Occupied bypass
31
Occupied mode
In occupied mode, the controller maintains the zone temperature based on the occupied heating
or cooling setpoints. The controller uses the occupied mode as a default mode when other forms
of occupancy request are not present. The fan will run continuously. The outdoor air damper will
close when the fan is off. The temperature setpoints can be local (hard-wired), communicated, or
stored default values (configurable using the Rover service tool).
Unoccupied mode
In unoccupied mode, the controller attempts to maintain the zone temperature based on the
unoccupied heating or cooling setpoint. The fan will cycle between high speed and off. The outdoor
air damper will remain closed, unless economizing. The controller always uses the stored default
setpoint values (configurable using the Rover service tool), regardless of the presence of a hardwired or communicated setpoint value.
Occupied standby mode

The controller is placed in occupied standby mode only when a communicated occupied request
is combined with an unoccupied request from occupancy binary input BI3. In occupied standby
mode, the controller maintains the zone temperature based on the occupied standby heating or
cooling setpoints. Because the occupied standby setpoints are typically spread 2F (1.1C) in either
direction and the outdoor air damper is closed, this mode reduces the demand for heating and
cooling the space. The fan will run as configured (continuous or cycling) for occupied mode. The
controller always uses the stored default setpoint values (configurable using the Rover service
tool), regardless of hard-wired or communicated setpoint values. In addition, the outdoor air
damper uses the Economizer Occupied Standby Minimum Position setpoint to reduce the
ventilation rate.
Occupied bypass mode

The controller is placed in occupied bypass mode when the controller is operating in the
unoccupied mode and either the timed override ON button on the Trane zone sensor is pressed or
the controller receives a communicated occupied bypass signal from a BAS. In occupied bypass
mode, the controller maintains the zone temperature based on the occupied heating or cooling
setpoints. The fan will run as configured (continuous or cycling). The outdoor air damper will close
when the fan is off. The controller will remain in occupied bypass mode until either the CANCEL
button is pressed on the Trane zone sensor or the occupied bypass time (configurable using the
Rover service tool) expires. The temperature setpoints can be local (hard-wired), communicated,
or stored default values (also configurable using the Rover service tool).
Timed override control

If the zone sensor has a timed override option (ON/CANCEL buttons), pushing the ON button initiates
a timed override on request. A timed override on request changes the occupancy mode from
unoccupied mode to occupied bypass mode. In occupied bypass mode, the controller controls the
zone temperature based on the occupied heating or cooling setpoints. The occupied bypass time,
which resides in the Tracer ZN521 and defines the duration of the override, is configurable from 0
to 240 minutes (default value of 120 minutes). When the occupied bypass time expires, the unit
transitions from occupied bypass mode to unoccupied mode. Pushing the CANCEL button cancels
the timed override request. A timed override cancel request will end the timed override before the
occupied bypass time has expired and will transition the unit from occupied bypass mode to
unoccupied mode.
If the controller is in any mode other than unoccupied when the ON button is pressed, the controller
still starts the occupied bypass timer without changing the mode to occupied bypass. If the
controller is placed in unoccupied mode before the occupied bypass timer expires, the controller
32
CNT-SVX07D-EN
will be placed in occupied bypass mode and remain in that mode until either the CANCEL button is
pressed on the Trane zone sensor or the occupied bypass time expires.
Zone temperature control

The Tracer ZN521 zone controller uses two methods of zone temperature control:
Cascade zone controlused in the occupied, occupied bypass, and occupied standby modes
Simplified zone controlused in the unoccupied mode
Cascade zone control

Cascade zone control maintains zone temperature by controlling the discharge air temperature to
control the zone temperature. The controller uses the difference between the measured zone
temperature and the active zone temperature setpoint to produce a discharge air temperature
setpoint. The controller compares the discharge air temperature setpoint with the discharge air
temperature and calculates a unit heating/cooling capacity accordingly (see Figure 1). The end
devices (outdoor air damper, valves, etc.) operate in sequence based on the unit heating/cooling
capacity (0100%).
Figure 18. Cascade zone control

Active zone
temperature
setpoint
Difference
Measured
zone
temperature
Calculated
discharge air
temperature
setpoint
Difference
Calculated unit
heating/cooling
capacity
Measured
discharge air
temperature
If the discharge air temperature falls below the Discharge Air Control Point Low Limit (configurable
using the Rover service tool) and cooling capacity is at a minimum, available heating capacity will
be used to raise the discharge air temperature to the low limit (see Discharge air tempering,
p. 33).
Simplified zone control

In the unoccupied mode, the controller maintains the zone temperature by calculating the required
heating or cooling capacity (0100%) according to the measured zone temperature and the active
zone temperature setpoint. The active zone temperature setpoint is determined by the current
operating modes, which include occupancy and heat/cool modes.
Discharge air tempering

If the controller is in cooling mode, cascade zone control initiates a discharge air tempering function
when the discharge air temperature falls below the Discharge Air Control Point Low Limit
(configurable using the Rover service tool) and all cooling capacity is at a minimum. The discharge
air tempering function allows the controller to provide heating capacity (if available) to raise the
discharge air temperature to the Discharge Air Control Point Low Limit.
The discharge air tempering function is often initiated under the following circumstances: Cold
outdoor air is brought in through the outdoor air damper when the damper is at (a high) minimum
CNT-SVX07D-EN
33
position, causing the discharge air temperature to fall below the Discharge Air Control Point Low
Limit.
Morning warm-up
Morning warm-up can occur any time the controller is in the occupied mode. The controller supply
fan always runs in the occupied mode.
Morning warm-up is initiated when the zone temperature is more than 2F (1.1C) below the
occupied heating setpoint. Morning warm-up is terminated when the zone temperature is less than
2F (1.1C) below the occupied heating setpoint.
When morning warm-up is terminated, the ZN520 runs in occupied heat mode. The outdoor air
damper will be closed when the zone temperature is 3F (1.7C) or more below the occupied heating
setpoint. The outdoor air damper will be at the minimum position when the zone temperature is
2F (1.1C) or less below the occupied heating setpoint. The outdoor air damper modulates
between the minimum position and closed as the zone temperature goes from 2F (1.1C) below
the occupied heating setpoint to 3F (1.7C) below the occupied heating setpoint.
Morning cool-down
Morning cool-down is initiated when the controller transitions from unoccupied to occupied and
the zone temperature is 3F (1.7C) above the occupied cooling setpoint. The fan will turn on and
the outdoor air damper will remain closed. The damper modulates between closed and the
minimum position as the zone temperature cools down toward the occupied cooling setpoint.
The damper will be closed when the zone temperature is more than 3F (1.7C) above the occupied
cooling setpoint. The damper will be at the minimum position when the zone temperature is less
than 2F (1.1C) above the occupied cooling setpoint. If economizing is possible, the damper will
open up above the minimum position. Cool down can only happen once.
When the outdoor air damper gets to its minimum position, morning cool-down is over and cannot
happen again until the next transition from unoccupied to occupied.
The controller will be in the occupied cooling mode when morning cool-down is over.
Heating or cooling mode

The heating or cooling mode can be determined in one of two ways:
By a communicated signal from a BAS or a peer controller
Automatically, as determined by the controller
A communicated heating signal permits the controller to heat only. A communicated cooling signal
permits the controller to cool only. A communicated auto signal allows the controller to
automatically change from heating to cooling and vice versa.
In heating and cooling mode, the controller maintains the zone temperature based on the active
heating setpoint and the active cooling setpoint, respectively. The active heating and cooling
setpoints are determined by the occupancy mode of the controller.
For two-pipe and four-pipe changeover units, normal heat/cool operation will not begin until the
ability to conduct the desired heating or cooling operation is verified. This is done using the
entering water temperature sampling function, for which a valid entering water temperature is
required. When neither a hard-wired nor a communicated entering water temperature value is
present on changeover units, the controller will operate in heating mode only and assume the coil
water is hot. The sampling function is not used.
The entering water temperature sampling function is used only for changeover applications. It is
used for information and troubleshooting only and does not affect the operation of the controller.
(For more information, see Entering water temperature sampling function, p. 35.)
34
CNT-SVX07D-EN
Entering water temperature sampling function

The entering water temperature sampling function is used with two-pipe and four-pipe changeover
units and requires a valid entering water temperature value. If the entering water temperature
value is less than 5F (2.8C) above a valid zone temperature value for hydronic heating and greater
than 5F (2.8C) below a valid zone temperature value for hydronic cooling, the sampling function
is enabled. When the sampling function is enabled, the controller opens the main hydronic valve
to allow the water temperature to stabilize. After 3 minutes, the controller again compares the
entering water temperature value to the zone temperature value to determine if the desired heating
or cooling function can be accomplished. If the entering water temperature value remains out of
range to accomplish the desired heating/cooling function, the controller closes the main hydronic
valve and waits 60 minutes to attempt another sampling. If the entering water temperature value
falls within the required range, it resumes normal heating/cooling operation and disables the
sampling function.
Fan operation
The Tracer ZN521 supports up to three fan speeds. Every time the fan is enabled, the fan will begin
operation and run on high speed for a period of time (0.5 seconds for fan coils and 3 seconds for
unit ventilators and blower coils) before changing to any other speed. This is done to provide
adequate torque to start the fan motor from the off position. The fan will always operate
continuously while either heating or cooling during occupied, occupied standby, and occupied
bypass operation. During unoccupied operation, the fan will cycle between off and high regardless
of the fan configuration. The controller can be configured to auto, to a specific fan speed, or to off.
If both a communicated and hard-wired value (fan-speed switch) is present, the communicated
value has priority.
Note: In occupied mode, The Tracer ZN521 zone controller requires continuous fan operation
because of cascade zone control. In unoccupied mode, the fan cycles.
When the controller receives a communicated auto signal (or the associated fan-speed switch is
set to AUTO with no communicated value present), the fan will operate in the auto mode. In the auto
mode, the fan will operate according to the fan default (configurable using the Rover service tool).
The fan speed can be configured to default to auto, a specific speed, or off for both heating and
cooling operation.
Configured as auto and with multiple speeds available, the fan will automatically switch speeds
depending on the difference between the zone temperature and the active zone temperature
setpoint. The fan speed will increase as the difference increases and decrease as the difference
decreases.
When the controller receives a communicated fan-speed signal (high, medium, low) or the
associated fan-speed switch is set to a specific fan speed, the fan will run continuously at the
desired fan speed during occupied, occupied standby, and occupied bypass operation. During
unoccupied operation, the fan will cycle between off and high regardless of the communicated fanspeed signal or fan-speed switch setting (unless either of these is off, which will control the fan off).
The fan will turn off when the controller receives a communicated off signal, when the fan-speed
switch is set to OFF, when specific diagnostics are generated, or when the default fan speed is set
to off and the fan is operating in the auto mode.
The ability to enable or disable the controllers associated fan speed switch is configurable.
Exhaust control
Exhaust control is accomplished by a single-speed exhaust fan or a two-position exhaust damper.
BOP2 controls this function. To enable exhaust control, configure the controller by selecting
Exhaust Fan/Damper Present and by selecting the number of fan speeds as either One or Two.
The exhaust function is coordinated with the supply fan and outdoor/return air dampers as follows:
CNT-SVX07D-EN
35
The exhaust output is energized only when the supply fan is operating and the outdoor air
damper position (%) is greater than or equal to the Exhaust Fan/Damper Enable Setpoint
(configurable using the Rover service tool).
The exhaust output is de-energized if the outdoor air damper position drops 10% below the
Exhaust Fan/Damper Enable Setpoint.
If the Exhaust Fan/Damper Enable Setpoint is less than 10%, the exhaust output is energized if
the outdoor air damper position is at the setpoint and de-energized at 0.
Valve operation
The Tracer ZN521 zone controller supports one or two tri-state modulating or two-position valves,
depending on the application (see Table 8). The controller opens and closes the appropriate
valve(s) to maintain the active zone temperature setpoint at the heating setpoint in heating mode
or the cooling setpoint in cooling mode (see Cascade zone control, p. 33). For face-and-bypass
applications, one or two isolation valves are controlled.
Table 8.
Valve control options

Tri-state
modulating
Two-position
Hydronic/steam fan coils and blower coils
Unit ventilators with valve control
Application
Face-and-bypass unit ventilators
Isolation
(two-position)
Modulating valve operation

The Tracer ZN521 supports tri-state modulating valve control. Two binary outputs control each
valve: one to drive the valve open and one to drive the valve closed. The stroke time for each valve
is configurable using the Rover service tool. The controller supports heating, cooling, or heat/cool
changeover with a single valve/coil for two-pipe applications. The controller supports cooling or
heat/cool changeover with the main valve/coil and heating only with the auxiliary valve/coil for
four-pipe applications. The controller moves the modulating valve to the desired positions based
on heating or cooling requirements.
Modulating valve calibration

Calibration of modulating valves is done automatically. During normal operation, the controller
overdrives the actuator (135% of the stroke time) whenever a position of 0% or 100% is requested.
as part of Tracer ZN521 normal operation. At power-up or after a power outage, the controller first
drives all modulating valves (and dampers) to the closed position. The controller calibrates to the
fully closed position by overdriving the actuator (135% of the stroke time). Then, the controller
resumes normal operation.
Two-position valve operation

The Tracer ZN521 supports two-position valves with a single binary output for each valve.
Controllers used for two-pipe applications support heating, cooling, or heat/cool changeover with
a single valve/coil. Controller used for four-pipe applications support cooling or heat/cool
changeover with a main valve/coil, and heating only with an auxiliary valve/coil.
Isolation-valve operation
See Face-and-bypass damper operation, p. 39.
36
CNT-SVX07D-EN
Two-pipe operation
For two-pipe applications, the Tracer ZN521 can be configured as heating only, cooling only, or
heat/cool changeover. The coil can be used as the primary heating source and/or the primary
cooling source. If present, an electric heating element can be used only as the primary heating
source (instead of hydronic or steam heating). A changeover unit requires a valid entering water
temperature valueeither communicated or hard-wiredto operate properly (see AI1: Entering
water temperature, p. 16 and Entering water temperature sampling function, p. 35).
Four-pipe operation
For four-pipe applications, the Tracer ZN521 can be configured as heat/cool or heat/cool
changeover. The main coil can be used as the primary cooling source or the primary heating/
cooling source. The auxiliary coil can be used only as the primary heating source, not as a second
stage of heating. During normal operation, the controller never uses the main coil and auxiliary coil
simultaneously. A changeover unit requires a valid entering water temperature valueeither
communicated or hard-wiredto operate properly (seeAI1: Entering water temperature, p. 16
and Entering water temperature sampling function, p. 35). Electric heat control is not available
on four-pipe applications.
Modulating outdoor/return air dampers

The Tracer ZN521 operates the modulating outdoor/return air dampers according to the following
factors:
Occupancy mode
Outdoor air temperature (communicated or hard-wired sensor)
Zone temperature
Setpoint
Discharge air temperature setpoint
The minimum position for an outdoor air damper is configurable using the Rover service tool for
occupied and occupied standby modes and for low-speed fan operation. A controller can also
receive a BAS-communicated outdoor air damper minimum position.
A BAS-communicated minimum position setpoint has priority over all locally configured setpoints.
When a communicated minimum position setpoint is not present, the controller uses the
configured minimum position for low fan speed whenever the fan is running at low speed,
regardless of the occupancy state. See Table 9 and Table 10 for more information about how the
controller determines the position of the modulating outdoor air damper.
Table 9.
Modulating outdoor air damper position setpoint determination

Occupancy
BAS-communicated
setpoint
Fan speed
Active minimum setpoint
Unoccupied
Any value
Any value
0% (closed)
Occupied
Occupied bypass
Occupied standby
Valid
Any value
BAS-communicated
Occupied
Occupied bypass
Occupied standby
Invalid
Low
Occupied low fan minimum
Occupied
Occupied bypass
Invalid
Medium/high
Occupied minimum
Occupied standby
Invalid
Medium/high
Occupied standby minimum
CNT-SVX07D-EN
37
Table 10. Relationship between outdoor temperature sensors and damper position
Modulating outdoor air damper position
Occupied or occupied
bypass
Occupied standby
Unoccupied
No or invalid outdoor air

temperature
Open to occupied
minimum position
Open to occupied standby

minimum position
Closed
Failed outdoor air sensor
Open to occupied
minimum position

minimum position
Closed
Outdoor air temperature present

and economizing possible1
Economizing; damper controlled

between
occupied minimum
position and 100%
Economizing; damper controlled

between
occupied standby
minimum position and 100%
Open and economizing during

unit operation; otherwise closed
Outdoor air temperature present

and economizing not possible1
Open to occupied minimum

position

minimum position
Closed
For an explanation of the economizing feature, see Economizing (free cooling), p. 38.
ASHRAE Cycle 1 conformance

Tracer ZN521 applications with an outside air damper support ASHRAE Cycle 1 conformance.
ASHRAE Cycle 1 operation admits 100% outdoor air at all times except during a warm-up cycle. A
tri-state modulating damper actuator is required for this operation. For Tracer ZN521 ASHRAE
Cycle 1 conformance, configure the minimum position of the economizer setpoint to 100% open
during occupied periods. If the zone temperature drops 3F (1.7C) below the active zone
temperature setpoint, the Tracer ZN521 closes the outdoor air damper regardless of the minimum
position setpoint.
ASHRAE Cycle 2 conformance

Tracer ZN521 controller applications with modulating outside air damper support ASHRAE Cycle
2 conformance. ASHRAE Cycle 2 operation allows the modulating outdoor air damper to
completely close when the zone temperature drops 3F (1.7C) or more below the active zone
temperature setpoint. If the zone temperature rises to within 2F (1.2C) of the active setpoint, the
damper opens to the occupied or occupied standby minimum damper positions. If the zone
temperature is between 2F and 3F (1.2C and 1.7C) below the active zone temperature setpoint,
the damper modulates between the minimum position and closed.
If the discharge air temperature is between the discharge air temperature low limit and the
discharge air temperature low setpoint, the damper modulates between the minimum position and
closed. If this situation is concurrent with ASHRAE Cycle 2 operation, the lesser of the two setpoints
will determine the actual damper position.
Economizing (free cooling)

Cooling with outdoor air, when the temperature is low enough to make this possible, is referred
to as economizing or free cooling. Tracer ZN521 controller applications with modulating outside
air damper support economizing. The modulating outdoor air damper provides the first source of
cooling for the Tracer ZN521. The controller initiates economizing if the outdoor air temperature is
below the economizer enable point (configurable using the Rover service tool). If economizing is
initiated, the controller modulates the outdoor air damper (between the active minimum damper
position and 100%) to control the amount of outdoor air cooling capacity. When the outdoor air
temperature rises 5F (2.8C) above the economizer enable point, the controller disables
economizing and moves the outdoor air damper back to its predetermined minimum position
based on the current occupancy mode or communicated minimum outdoor air damper position.
If an outdoor air temperature value is not present, economizing is disabled.
38
CNT-SVX07D-EN
Two-position control of a modulating outdoor air damper

The Tracer ZN521 does not support a two-position outdoor air damper actuator. However, a
modulating outdoor/return air damper actuator can be used for two-position control. Two-position
control can be accomplished by not providing an outdoor air temperature (neither hard-wired nor
communicated) to the controller, and by setting the damper minimum position (using the Rover
service tool) to the desired value (typically, 100%).
Face-and-bypass damper operation

The Tracer ZN521 can control a face-and-bypass damper to modulate a percentage of air to the face
of the coil(s) and around (bypass) the coil(s) to maintain zone comfort. For two-pipe changeover
applications, if the controller requests heating and hot water is available, the face-and-bypass
damper modulates to the face position. If the controller requests heating and hot water is not
available, the face-and-bypass damper remains in the bypass position, and water sampling may
be initiated (see Entering water temperature sampling function, p. 35). For four-pipe changeover
applications, both heat and cool capacity are assumed to be available.
Face-and-bypass, isolation-valve operation

A Tracer ZN521 with a face-and-bypass damper controls on/off isolation valve(s) to prevent
unwanted water flow through the coil(s) when no airflow is passing over the coil (100% bypass).
In two-pipe applications, the isolation valve stops water flow, preventing radiant heat (heating
mode) and excessive condensate (cooling mode) from the coil. In four-pipe applications, the
isolation valves are used to prevent simultaneous heating and cooling.
The heating or cooling isolation valve opens whenever capacity is requested (>0%) as the face-andbypass damper begins to modulate toward the coil face. The isolation valve closes when capacity
returns to 0%.
DX cooling operation
The Tracer ZN521 supports one stage of direct expansion (DX) compressor operation for cooling
only.
Note: The controller does not use the DX compressor and economizing simultaneously. Not doing
so prevents short cycling from occurring if the entering air temperature is too low for the
evaporator coil to operate as designed.
Electric heat operation

The Tracer ZN521 supports both single-stage and two-stage electric heat. Electric heat is cycled on
and off to maintain the discharge air temperature at the active heating setpoint. Two-pipe
changeover units with electric heat use the electric heat only when hot water is not available. The
use of both electric and hydronic heat is not supported.
Baseboard heat operation

When configured for baseboard heat output, the controller turns on baseboard heat at 2.2F (1.2C)
below the active heating setpoint, and turns off baseboard heat at 0.8F (0.4C) below the active
heating setpoint. The range for activating the baseboard heat cannot be adjusted; however, the
heating setpoint is configurable using the Rover service tool.
Baseboard heating is used most effectively when the discharge air temperature control high limit
is set below 100F (56C). If this is done, the unit heat will maintain the temperature on light load
days and the baseboard heat will be enabled to maintain the temperature on heavier load days.
CNT-SVX07D-EN
39
Dehumidification
The Tracer ZN521 supports a dehumidification feature. Dehumidification is possible if the following
are present:
Mechanical cooling is available
The heating capacity is located in the reheat position
A zone humidity sensor is connected at AI4, or a relative humidity (RH) value is transmitted to
the controller by a BAS.
The Space RH Setpoint is valid (configurable using the Rover service tool)
Dehumidification is enabled using the Rover service tool
The controller initiates dehumidification if the zone humidity exceeds the humidity setpoint. The
controller continues to dehumidify until the sensed humidity falls below the setpoint minus the
relative humidity offset.
The controller uses cooling and heating capacities simultaneously to dehumidify the space. While
dehumidifying, the controller maintains the zone temperature at the active setpoint.
Note: Dehumidification is not available for face-and-bypass applications, and cannot be used if
the unit is in the unoccupied mode. Dehumidification disables the economizing function.
Peer-to-peer communication
Tracer ZN521 zone controllers have the ability to share data with other LonTalk-based controllers.
Multiple controllers can be bound as peers, using the Rover service tool, to share:
Setpoint
Zone temperature
Heating/cooling mode
Fan status
Unit capacity control
Shared data is communicated from one controller to any other controller that is bound to it as a
peer. Applications having more than one unit serving a single zone can benefit by using this feature;
it allows multiple units to share a single zone temperature sensor and prevents multiple units from
simultaneously heating and cooling.
Unit protection strategies

The following strategies are initiated when specific conditions exist in order to protect the unit or
building from damage:
40
Smart reset
Low-coil-temperature protection
Condensate overflow
Fan status
Fan off delay
Filter-maintenance timer
Freeze avoidance
Freeze protection (discharge air temperature low limit)
CNT-SVX07D-EN
Smart reset
The Tracer ZN521 will automatically restart a unit that is locked-out as a result of a Low Coil Temp
Detection (BI1) diagnostic. Referred to as smart reset, this automatic restart will occur 30 minutes
after the diagnostic occurs. If the unit is successfully restarted, the diagnostic is cleared. If the unit
undergoes another Low Coil Temp Detection diagnostic within a 24-hour period, the unit will be
locked out until it is manually reset. (For more information on manual resetting, see Manual
(latching) diagnostics, p. 48).
Low-coil-temperature protection
See BI1: Low-coil-temperature detection, p. 14 and Smart reset in the current section.
Condensate overflow
See BI2: Condensate overflow, p. 14.
Fan status
The fan status is based on the status of the binary output(s) dedicated to fan control. The fan status
is reported as high, medium, or low whenever the corresponding binary output is energized. The
fan status is reported as off whenever none of the fan binary outputs are energized.
Additionally, a fan-status switch can be connected to BI4 to monitor the status of the fan for beltdriven or direct-driven units. The fan status switch provides feedback to the controller. If the fan is
not operating when the controller has the fan controlled to on, the controller will generate a Low
AirFlowFan Failure diagnostic.
If the controller energizes the fan output for 1 minute, and the fan status switch indicates no fan
operation, the controller performs a unit shutdown and generates a Low AirFlowFan Failure
diagnostic. If the fan has been operating normally for one minute, but the fan status switch
indicates no fan operation, the same diagnostic is generated. This manual diagnostic discontinues
unit operation until the diagnostic has been cleared from the controller. If a diagnostic reset is sent
to the controller and the fan condition still exists, the controller attempts to run the fan for 1 minutes
before generating another diagnostic and performing a unit shutdown.
Fan off delay

After heating has been controlled off, the Tracer ZN521 keeps the fan energized for an additional
30 seconds. The purpose of this feature is to remove residual heat from the heating source.
Filter-maintenance timer
The filter-maintenance timer tracks the amount of time (in hours) that the fan is enabled. The
Maintenance Required Timer Setpoint (configurable using the Rover service tool) is used to set the
amount of time until maintenance (typically, a filter change) is needed. If the setpoint is configured
to zero, the filter-maintenance timer is disabled.
The controller compares the fan-run time to Maintenance Required Timer Setpoint. Once the
setpoint is reached, the controller generates a Maintenance Required diagnostic. When the
diagnostic is cleared, the controller resets the filter-maintenance timer to zero, and the timer begins
accumulating fan-run time again.
Freeze avoidance
Freeze avoidance is used for low ambient temperature protection. It is initiated only when the fan
is off. The controller enters the freeze-avoidance mode when the outdoor air temperature is below
the Freeze Avoidance Setpoint (configurable using the Rover service tool). The controller disables
freeze avoidance when the outdoor air temperature rises 3F (1.7C) above the Freeze Avoidance
Setpoint.
When the controller is in freeze-avoidance mode:
CNT-SVX07D-EN
41
Valves are driven open to allow water to flow through the coil
Fan is off
Face-and-bypass damper (when present) is at full bypass
Economizing is disabled
The outdoor/return air damper is closed
DX cooling is off
Electric heat stages are off
Freeze protection (discharge air temperature low limit)

The controller monitors the discharge air temperature with a 10 k thermistor wired to analog
input AI2. The freeze-protection operation is initiated whenever the discharge air temperature falls
below the Discharge Air Temperature Low Limit. The Discharge Air Temperature Low Limit is
configurable using the Rover service tool. During freeze protection, the controller increases the
heating capacity or decreases the cooling capacity in order to raise the discharge air temperature
above the low limit. If the discharge air temperature remains below the low limit for 3 minutes, the
controller generates a Discharge Air Temp Limit diagnostic. See Table 16, p. 49 for the effects of this
diagnostic on outputs.
42
CNT-SVX07D-EN
Status indicators for operation and communication

This chapter describes the operation and communication status indicators on the Tracer ZN521
controller, including:
A description of the location and function of the Test button and Service pin button and the lightemitting diodes (LEDs) located on the controller
A complete list of the diagnostics that can occur, their effect on controller outputs, and an
explanation of how diagnostics are cleared and the device restored to normal operation
Test button
The Test button is used to perform the manual output test (see Manual output test on page 43),
which verifies that the controller output devices are operating properly. It is located on the Tracer
ZN521 circuit board as shown in Figure 19. You must remove the cover to access the Test button.
Figure 19. Tracer ZN521 zone controller circuit board
Green (status)
LED
Test button
Neuron ID label
Red (service) LED

Service pin button
Yellow
(communication)
LED
Manual output test

The manual output test sequentially turns on and off all binary outputs to verify their operation.
The test overrides normal operation of the controller, which is suspended while the test is being
performed.
Use the manual output test to:
Verify output wiring and operation
Force the water valve(s) open to balance the hydronic system
Clear diagnostics and restore normal operation (although not a primary function of the manual
output test)
The manual output test is performed either by repeatedly pressing the Test button to proceed
through the test sequence or by using the Rover service tool. Table 11 on page 45 lists the outputs
for non-face-and-bypass unit configurations in the sequence in which they are verified; Table 12 on
page 46 lists the outputs for face-and-bypass unit configurations in the sequence in which they are
verified.
CNT-SVX07D-EN
43
The procedure is as follows:

1. Press and hold the Test button for 3 to 4 seconds, then release it to start the test mode. The green
(status) LED goes off when you press the Test button, and then it blinks (as described in Table 14
on page 47) when the Test button is released to indicate that the controller is in manual test
mode.
2. Press the Test button (no more than once per second) to advance through the test sequence.
Table 11 and Table 12 show the resulting activities of the binary outputs.
Note: The outputs are not subject to minimum on or off times during the test sequence.
44
CNT-SVX07D-EN
BOP8
BOP9
BOP10
1)Generic
2)Baseboard heat
BOP7
Outdoor air damper, close
BOP6
Outdoor air damper, open
BOP5
1)Heating valve, close

2)Electric heat, stage 2
Fan high
BOP4
1)Heating valve, open

2)Two-position heat valve
3)Electric heat, stage 1
BOP3
Cooling/changeover
valve, close
BOP2
1)Cooling/changeover
valve, open
2)Two-position cooling/
changeover valve
3)DX compressor
BOP1
Fan low
Result
1)Fan medium
2)Exhaust
Step
Number of times
Test button is pressed
in sequence)
CNT-SVX07D-EN
Table 11. Manual output test sequence for non-face-and-bypass configurations
Begins test
mode1
Off
Off
Off
Off
On/Close
Off
1) On/Close
2) Off
Off
On/Close
Off
Fan high2
On/High
Off
Off
Off
Off
Off
Off
Off
Off
Off
Fan
medium3
Off
1) On/Med
2) Off
Off
Off
Off
Off
Off
Off
Off
Off
Fan low4
Off
Off
On/Low
Off
Off
Off
Off
Off
Off
Off
Main open,
DX on
On/High
Off
Off
On/Open
Off
Off
Off
Off
Off
Off
Main close,
DX off, aux
open, EH1
on
On/High
Off
Off
Off
On/Close
On/Open
Off
Off
Off
Off
Aux open,
EH1 on,
exhaust
fan5
On/High
1) Off
2) On
Off
Off
Off
On/Open
Off
Off
Off
Off
Aux close,
EH1 off,
EH2 on,
damper
open
On/High
Off
Off
Off
Off
Off
On/Close
On/Open
Off
Off
Damper
close
On/High
Off
Off
Off
Off
Off
Off
Off
On/Close
Off
10
Generic/
baseboard
heat
energized6
On/High
Off
Off
Off
Off
Off
Off
Off
Off
On
11: Exit5
1
2
3
4
5
6
The controller turns off all fan and electric heat outputs and drives all dampers and valves closed.
The controller attempts to clear all diagnostics.
If configured for a 3-speed fan, the medium fan speed output will energize at step 3. If configured for a 2-speed fan, the fan remains on high speed at step 3.
If configured for a 3-speed fan, the medium fan speed output energizes at step 4. If configured for a 2-speed fan, the low fan speed output energizes at step 4. If configured
for a 1-speed fan, the fan remains on high speed at step 4.
If the unit is configured for a 1- or 2-speed fan, the exhaust fan output energizes on step 7. The exhaust fan output is shared with medium fan speed.
After step 10, the manual output test performs an exit, which initiates a reset to restore the controller to normal operation.
45
BOP9
BOP10
1)Generic
2)Baseboard heat
BOP8
Outdoor air damper, close
BOP7
Outdoor air damper, open
BOP6
Face and bypass damper,

close (bypass)
BOP5
Two-position heat valve
Fan high
BOP4
Face and bypass damper,

open to face
BOP3
Two-position cool/
changeover valve
BOP2
Fan low
BOP1
1)Fan medium
2)Exhaust fan
Result
Number of times
Test button is pressed
in sequence)
Step
Begins test
mode1
Off
Off
Off
Off
Off
Off
On/Close
Off
On/Close
Off
Fan high2
On/High
Off
Off
Off
On/Open
Off
Off
Off
Off
Off
Fan
medium3
Off
1) On/Med
2) Off
Off
Off
On/Open
Off
Off
Off
Off
Off
Fan low4
Off
Off
On/Low
Off
On/Open
Off
Off
Off
Off
Off
Main open,
DX on
On/High
Off
Off
On/Open
On/Open
Off
Off
Off
Off
Off
Main close,
DX off, aux
open
On/High
Off
Off
Off
On/Open
On/Open
Off
Off
Off
Off
Aux open,
EH1 on,
exhaust
fan5
On/High
1) Off
2) On
Off
Off
On/Open
On/Open
Off
Off
Off
Off
Aux close,
damper
open
On/High
Off
Off
Off
Off
Off
On/Close
On/Open
Off
Off
Outdoor air
damper
close
On/High
Off
Off
Off
Off
Off
On/Close
Off
On/Close
Off
10
Generic/
baseboard
heat
energized6
On/High
Off
Off
Off
Off
Off
On/Close
Off
Off
On
11: Exit5
CNT-SVX07D-EN
1
2
3
4
5
6
The controller turns off all fan and electric heat outputs and drives all dampers and valves closed.
The controller attempts to clear all diagnostics.
If configured for a 3-speed fan, the medium fan speed output will energize at step 3. If configured for a 2-speed fan, the fan remains on high speed at step 3.
If configured for a 3-speed fan, the medium fan speed output energizes at step 4. If configured for a 2-speed fan, the low fan speed output energizes at step 4. If configured
for a 1-speed fan, the fan remains on high speed at step 4.
If the unit is configured for a 1- or 2-speed fan, the exhaust fan output energizes on step 7. The exhaust fan output is shared with medium fan speed.
After step 10, the manual output test performs an exit, which initiates a reset to restore the controller to normal operation.
46
Table 12. Manual output test sequence for face-and-bypass configurations (two-position isolation valves only)
Service pin button

The Service pin button is located as shown in Figure 19 on page 43. The Service pin button is used
to:
Identify a device (see Identifying a device in the Rover Installation/Operation/Programming

guide (EMTX-SVX01A-EN)
Add a device to the active group (see Adding a device in EMTX-SVX01A-EN)
Verify PCMCIA communications (see Verifying PCMCIA communications in EMTX-SVX01AEN)
Make the green (status) LED wink to verify that the controller is communicating on the link
(see Table 14 on page 47 and Setting the Auto-wink option in EMTX-SVX01A-EN)
Interpreting LEDs
The red (service) LED on the Tracer ZN521 controller (see Figure 19 on page 43) indicates whether
the controller is capable of operating normally (see Table 13).
Table 13. Red LED: Service indicator
LED activity
Explanation
LED is off continuously when power is applied

to the controller.
The controller is operating normally.
LED is on continuously when power is applied

to the controller.
The controller is not working properly, or

someone is pressing the Service pin button.
LED flashes once every second.
The controller is not executing the application

software because the network connections
and addressing have been removed.1
1 Restore the controller to normal operation using the Rover service tool. Refer to EMTX-SVX01AEN for more information.
The green (status) LED on the Tracer ZN521 controller (see Figure 19 on page 43) indicates whether
the controller has power applied to it and if the controller is in manual test mode (see Table 14).
Table 14. Green LED: Status indicator
LED activity
LED is on continuously.
Power is on (normal operation).
LED blinks (one recurring blink).
Manual output test mode is being performed

and no diagnostics are present.
LED blinks (blinks twice as a recurring

sequence).
Manual output test mode is being performed

and one or more diagnostics are present.
LED blinks (1/4 second on,

1/4 second off for 10 seconds).
The Auto-wink option is activated, and the

controller is communicating.1
LED is off continuously.
Either the power is off,

the controller has malfunctioned, or
the Test button is being pressed.
CNT-SVX07D-EN
Explanation
By sending a request from the Rover service tool, you can request the controllers green LED
to blink (wink), a notification that the controller received the signal and is communicating.
47
The yellow (communications) LED on the Tracer ZN521 controller (see Figure 19 on page 43)
indicate the controllers communication status (see Table 15).
Table 15. Yellow LED: Communications indicator
LED activity
Explanation
LED is off continuously
The controller is not detecting any

communication (normal for stand-alone
applications).
LED blinks.
The controller detects communication (normal

for communicating applications, including
data sharing).
LED is on continuously.
Problem with communication link wiring

(possible need for termination resistor), or
controller failure (caused by power surge,
lightning strike, etc.)
Diagnostics
Diagnostics are informational messages that indicate the operational status of the controller. In
response to most diagnostics, the controller attempts to protect the equipment by enabling or
disabling, or opening or closing, specific outputs. Other diagnostics provide information about the
status of the controller, but have no effect on outputs. Diagnostics are reported in the order in which
they occur. Multiple diagnostics can be present simultaneously. Diagnostic messages are viewed
using the Rover service tool or through a BAS.
Types of diagnostics
Diagnostics are categorized according to the type of clearing method each uses and the type of
information each provides.
The four categories are:
Manual (latching)
Automatic (nonlatching)
Smart reset
Informational
Note: Clearing diagnostics refers to deleting diagnostics from the software; it does not affect the
problem that generated the message. For help with diagnosing a problem, see
Troubleshooting, p. 51.
Manual (latching) diagnostics

Manual diagnostics (also referred to as latching) cause the unit to shut down. Manual diagnostics
can be cleared from the controller in one of the following ways:
By using the Rover service tool (see Resetting a diagnostic in EMTX-SVX01A-EN, Rover
Installation/Operation/and Programming guide).
Through a building automation system (see product literature)
By initiating a manual output test at the controller (see Manual output test on page 43)
By cycling power to the controller. When the 24 Vac power to the controller is cycled off and then
on again, a power-up sequence occurs.
By turning the zone sensor fan switch to OFF and then back to any other setting. (This feature
will be available beginning with controller software version 2.10.)
Automatic (nonlatching) diagnostics

Automatic diagnostics clear automatically when the problem that generated the diagnostic is
solved.
48
CNT-SVX07D-EN
Smart reset diagnostics

After the controller detects the first smart reset diagnostic, the unit waits 30 minutes before
initiating the smart reset function. If another diagnostic of this type occurs again within 24 hours
after an automatic clearing, you must clear the diagnostic manually by using any of the ways shown
for Manual (latching) diagnostics.
Informational diagnostics
Informational diagnostics provide information about the status of the controller. They do not affect
machine operation. They can be cleared from the controller using any of the ways shown for
Manual (latching) diagnostics.
Table of diagnostics
Table 16 presents each diagnostic that can be generated by the Tracer ZN521, its effect on outputs
(consequences), and its type.
Note: The generic binary output is unaffected by diagnostics.
Table 16. Diagnostics

Diagnostic
Probable cause
Consequences
Diagnostic
type
Maintenance Required
Fan run hours exceed the time set

to indicate filter change
Fan unaffected
Valves unaffected
Electric heat unaffected
Face and bypass damper unaffected
Informational
Condensate Overflow
The drain pan is full of water
Fan off
Valves closed
Outdoor air damper closed
Face and bypass damper bypass
DX/electric heat off
Baseboard heat off
Manual
Low Coil Temp Detection
The leaving fluid temperature

may be close to freezing
Fan off
Valves open
Baseboard heat off
Smart reset/
Manual
Low AirflowFan Failure
The fan drive belt, contactor, or

motor has failed.
Fan off
Valves closed
Baseboard heat off
Manual
Space Temperature Failure
Invalid or missing value for zone

temperature
Fan off
Valves closed
Baseboard heat off
Automatic
Entering Water Temp Failure

temperature
Fan unaffected (enabled)

Valves unaffected
Outdoor air damper unaffected
DX/electric heat unaffected
Baseboard heat off
Automatic
Discharge Air Temp Limit
Discharge air temperature has

fallen below the Discharge Air
Temperature Low Limit
Fan off
Valves open
Baseboard heat off
Automatic
CNT-SVX07D-EN
49
Table 16. Diagnostics (continued)

Diagnostic
Probable cause
Consequences
Diagnostic
type
Discharge Air Temp Failure
Invalid or missing value for

discharge air temperature
Fan off
Valves closed
DX cooling/electric heat off
Baseboard heat off
Automatic
Outdoor Air Temp Failure

outdoor air temperature
Fan unaffected
Valved unaffected
Outdoor air damper minimum
position
DX cooling/electric heat unaffected
Baseboard heat unaffected
Automatic
Humidity Input Failure

relative humidity
Fan unaffected
Valves unaffected
Dehumidification sequence off
Automatic
CO2 Sensor Failure
Invalid or missing value for CO2
Fan unaffected
Valves unaffected
Informational
Generic AIP Failure

generic analog input
Fan unaffected
Valves unaffected
Informational
Local Fan Mode Failure
Invalid or missing fan-speed

switch (reverts to default fan
speed)
Fan unaffected
Valves unaffected
Automatic
Local Setpoint Failure

temperature setpoint (reverts to
default setpoint)
Fan unaffected
Valves unaffected
Automatic
Generic Temperature Failure
Invalid or missing generic

temperature value
Fan unaffected
Valves unaffected
Informational
Invalid Unit Configuration
Software is configured
improperly
Fan off
Valves off
Face and bypass damper closed
DX cooling/electric heat off
Baseboard heat off
Manual
Normal
On start-up
Fan unaffected
Valves unaffected
Electric heat unaffected
Compressors unaffected
Damper unaffected
Automatic
50
CNT-SVX07D-EN
Troubleshooting
Use Table 17 through Table 22 to assist you in diagnosing any of the following operational
problems that you might encounter with the Tracer ZN521 zone controller:
Fan does not energize (Table 17)
Valves remain closed (Table 18 on page 52)
Valves remain open (Table 19 on page 52)
Compressors are not running (Table 20 on page 53)
Electric heat does not energize (Table 20 on page 53)
An outdoor air damper stays closed (Table 21 on page 53)
An outdoor air damper stays open (Table 22 on page 54)
Table 17. Fan does not energize

Probable cause
Explanation
Unit wiring
The wiring between the controller outputs and the fan relays and contacts must be present and correct for normal fan operation. Refer to applicable wiring diagram.
Failed end device
The fan motor and relay must be checked to ensure proper operation.
Normal operation
The fan will turn off when the controller receives a communicated off signal, when the
fan-speed switch is set to OFF, when specific diagnostics are generated, or when the
default fan speed is set to Off and the fan is operating in the Auto mode. If the controller
is in unoccupied mode, the fan cycles between off and the highest fan speed.
No power to the controller
If the controller does not have power, the unit fan does not operate. For the Tracer ZN521
controller to operate normally, it must have an input voltage of 24 Vac. If the green LED is
off continuously, the controller does not have sufficient power or has failed.
Power-up control-wait
If power-up control-wait is enabled (non-zero time), the controller remains off until one of
two conditions occurs:
1) The controller exits power-up control-wait after it receives communicated information.
2) The controller exits power-up control-wait after the power-up control-wait time expires.
Diagnostic present
Several diagnostics affect fan operation. For information about these diagnostics, see
Table 16, p. 49.
Unit configuration
The controller must be properly configured based on the actual installed end devices and
application. If the unit configuration does not match the actual end device, the fans may
not work correctly.
Manual output test
The controller includes a manual output test sequence you can use to verify output operation and associated output wiring. However, based on the current step in the test
sequence, the unit fan may not be on. Refer to the Manual output test, p. 43.
Random start
observed
After power-up, the controller always observes a random start from 5 to 30 seconds. The
controller remains off until the random start time expires.
Cycling fan operation/

continuous
The controller operates the fan continuously when in the occupied, occupied standby, or
occupied bypass mode. When the controller is in the unoccupied mode, the fan is cycled
between high speed and off with capacity.
Unoccupied operation
Even if the controller is configured for continuous fan operation, the fan normally cycles
with capacity during unoccupied mode. While unoccupied, the fan cycles on or off with
heating/cooling to provide varying amounts of heating or cooling to the space.
Fan mode off
If a local fan mode switch determines the fan operation, the off position controls the fan
off.
Requested mode off
You can communicate a desired operating mode (such as off, heat, and cool) to the controller. If off is communicated to the controller, the unit controls the fan off. There is no
heating or cooling.
CNT-SVX07D-EN
51
Troubleshooting
Table 18. Valves remain closed

Probable cause
Explanation
Unit wiring
The wiring between the controller outputs and the valve(s) must be present and correct
for normal valve operation. Refer to applicable wiring diagram.
Failed end device
The valves must be checked to ensure proper operation.
No power to the controller
If the controller does not have power, the unit valve(s) will not operate. For the Tracer
ZN521 controller to operate normally, you must apply an input voltage of 24 Vac. If the
green LED is off continuously, the controller does not have sufficient power or has failed.
Power-up control-wait
If power-up control-wait is enabled (non-zero time), the controller remains off until one of
two conditions occurs:
1) The controller exits power-up control-wait after it receives communicated information.
2) The controller exits power-up control-wait after the power-up control-wait time expires.
Diagnostic present
Several diagnostics affect valve operation. For information about these diagnostics, see
Table 16, p. 49.
Normal operation
The controller opens and closes the valves to meet the unit capacity requirements.
Unit configuration
application. If the unit configuration does not match the actual end device, the valves
may not work correctly.
Manual output test
sequence, the valves may not be open. Refer to the Manual output test, p. 43.
Random start
observed
After power-up, the controller always observes a random start from 5 to 30 seconds. The
controller remains off until the random start time expires.
Requested mode off
You can communicate a desired operating mode (such as off, heat, and cool) to the controller. If off is communicated to the controller, the unit controls the fan off. There is no
heating or cooling.
Entering water
temperature
sampling logic
The controller includes entering water temperature sampling logic, which is automatically initiated during 2-pipe and 4-pipe changeover if the entering water temperature is
either too cool or too hot for the desired heating or cooling. (See AI1: Entering water
temperature, p. 16.)
Valve configuration
Make sure the valves are correctly configured, using the Rover service tool, as normally
open or normally closed as dictated by the application.
Table 19. Valves remain open

Probable cause
Explanation
Unit wiring
The wiring between the controller outputs and the valve(s) must be present and correct
for normal valve operation. Refer to applicable wiring diagram.
Failed end device
The valves must be checked to ensure proper operations.
Normal operation
The controller opens and closes the valves to meet the unit capacity requirements.
Manual output test
sequence, the values may not be open. refer to the Manual output test, p. 43.
Diagnostic present
Several diagnostics affect valve operation. For information about these diagnostics, see
Table 16, p. 49.
Unit configuration
application. If the unit configuration does not match the actual end device, the valves may
not work correctly.
52
CNT-SVX07D-EN
Troubleshooting
Table 19. Valves remain open (continued)

Probable cause
Explanation
Entering water
temperature
sampling logic
The controller includes entering water temperature sampling logic, which is automatically
initiated during 2-pipe and 4-pipe changeover if the entering water temperature is either
too cool or too hot for the desired heating or cooling. (See AI1: Entering water temperature, p. 16.)
Valve configuration
Make sure the valves are correctly configured, using the Rover service tool, as normally
open or normally closed as dictated by the application.
Freeze avoidance
When the fan is off with no demand for capacity (0%) and the outdoor air temperature is
below the freeze avoidance setpoint, the controller opens the water valves (100%) to prevent coil freezing. This includes unoccupied mode when there is no call for capacity or
any other time the fan is off.
Table 20. DX or electric heat does not energize

Probable cause
Explanation
Unit wiring
The wiring between the controller outputs and the end devices must be present and correct for normal operation. Refer to applicable wiring diagram.
Failed end device
Check the control contactors or the electric heat element, including any auxiliary safety
interlocks, to ensure proper operation.
No power to the
controller
If the controller does not have power, heat outputs do not operate. For the Tracer ZN521
controller to operate normally, you must apply an input voltage of 24 Vac. If the green
LED is off continuously, the controller does not have sufficient power or has failed.
Diagnostic present
Several diagnostics affect DX and electric heat operation. For information about these
diagnostics, see Table 16, p. 49.
Normal operation
The controller controls compressor or electric heat outputs as needed to meet the unit
capacity requirements.
Unit
configuration
application. If the unit configuration does not match the actual end device, DX or electric
heat may not operate correctly.
Manual output test
sequence, the DX or electric heat outputs may be off. Refer to the Manual output test,
p. 43.
Requested mode off
You can communicate a desired operating mode (such as off, heat, and cool) to the controller. If off is communicated to the controller, the unit shuts off the compressor or electric heat.
Freeze avoidance
When the fan is off with no demand for capacity (0%) and the outdoor air temperature is
below the freeze avoidance setpoint, the controller disables compressors and electric
heat outputs (100%) to prevent coil freezing. This includes unoccupied mode when there
is no call for capacity or any other time the fan is off.
Table 21. Outdoor air damper remains closed

Probable cause
Explanation
Unit wiring
The wiring between the controller outputs and the outdoor air damper must be present
and correct for normal outdoor air damper operation. Refer to applicable wiring diagram.
Failed end device
Check damper actuator to ensure proper operation.
CNT-SVX07D-EN
53
Troubleshooting
Table 21. Outdoor air damper remains closed (continued)

Probable cause
Explanation
No power to the
controller
If the controller does not have power, the outdoor air damper does not operate. For the
Tracer ZN521 controller to operate normally, you must apply an input voltage of 24 Vac. If
the green LED is off continuously, the controller does not have sufficient power or has
failed.
Diagnostic present
Several diagnostics affect outdoor air damper operation. For information about these
diagnostics, see Table 16, p. 49.
Normal
operation
The controller opens and closes the outdoor air damper based on the controllers occupancy mode and fan status. Normally, the outdoor air damper is open during occupied
mode when the fan is running and closed during unoccupied mode.
Unit configuration
application. If the unit configuration does not match the actual end device, the outdoor air
damper may not work correctly.
Manual output test
sequence, the outdoor air damper may not be open. Refer to the Manual output test,
p. 43.
Warm-up and cooldown sequence
The controller includes both a morning warm-up and cool-down sequence to keep the
outdoor air damper closed during the transition from unoccupied to occupied. This is an
attempt to bring the space under control as quickly as possible.
Requested mode off
You can communicate a desired operating mode (such as off, heat, or cool) to the controller. If off is communicated to the controller, the unit closes the outdoor air damper.
Table 22. Outdoor air damper remains open

Probable cause
Explanation
Unit wiring
The wiring between the controller outputs and the outdoor air damper must be present
and correct for normal outdoor air damper operation. Refer to applicable wiring diagram.
Failed end device
Check damper actuator to ensure proper operation.
Normal
operation
The controller opens and closes the outdoor air damper based on the controllers occupancy mode and fan status. Normally, the outdoor air damper is open during occupied
mode when the fan is running and closed during unoccupied mode. (See Modulating
outdoor/return air dampers, p. 37.
Unit
configuration
application. If the unit configuration does not match the actual end device, the outdoor air
damper may not work correctly.
Manual output test
sequence, the outdoor air damper may be open. Refer to the Manual output test, p. 43.
54
CNT-SVX07D-EN
Index
Numerics
24 Vac wiring 10
A
AC-power wiring 10
Actuators
Damper 9, 39
Valve 9
Additional application-dependent
components 89
Addressing
LonTalk communication 11
Neuron IDs 11
Agency listing/compliance 7
Analog inputs 1417
AI1 (Entering water
temperature) 16
AI2 (Discharge air
temperature) 16
AI3 (Outdoor air
temperature) 16
AI3 configuration options 16
AI4 (Universal 420 mA) 17
AI4 configuration options 17
AI4 configured for CO2
measurement 17
AI4 configured for RH
measurement 17
AI4 generic configuration 17
FAN (Fan mode input) 15
Generic temperature 16
SET (Local setpoint) 15
ZN (Zone temperature) 15
Applications 6, 1330
Applications table 13
ASHRAE Cycle 1
Operation 38
ASHRAE Cycle 2
Operation 38
B
BAS communication 6, 11
Baseboard heat
Operation 39
Supported application 18
Binary inputs 1314
BI1 (Low-coil-temperature
detection) 14
BI2 (Condensate overflow) 14
BI3 (Occupancy or generic) 14
CNT-SVX07D-EN
BI3 configuration options 14

BI4 (Fan status) 14
Switching devices 9
Binary outputs 1819
Generic 19
Manual output test 43
Output devices 9
Overriding 19
Table of supported options 18
Blower coils 6, 18
Building automation system
communication 6, 11
C
CE, <Emphasis>see Agency listing/
compliance
Circuit board 43
Clearances 7
Clearing diagnostics 48
CO2
Measurement input 17
Sensor 9, 17
Sensor failure diagnostic 50
Condensate overflow
Diagnostic 49
Input 14
Switch 9, 14
Configuration options
AI3 (Outdoor air temperature or
generic) 16
AI4 (Generic, CO2 measurement,
or RH measurement) 17
BI3 (Occupancy or generic) 14
DX cooling 6
Electric heat 6
Face-and-bypass dampers 6
Outdoor/return air dampers 6
Rover service tool 6
Tri-state modulating dampers 6
Tri-state modulating valves 6
Two-position valves 6
Current-sensing switches 9
D
Dampers
Actuators 9
Exhaust 35
Face-and-bypass 6, 18, 39
Modulating outdoor/return
air 37, 39
Outdoor/return air 6, 18, 35, 37
Supported applications 6, 18
Tri-state modulating 6
Two-position control 39
Data sharing 40
Dehumidification 40
Device addressing for BAS
communication 11
Diagnosing operational
problems 5154
Diagnostics
Automatic 48
Clearing 48
CO2 Sensor Failure 50
Condensate Overflow 49
Discharge Air Temp Failure 50
Discharge Air Temp Limit 49
Entering Water Temp Failure 49
Freeze protection 49
Generic AIP Failure 50
Generic Temperature Failure 50
Humidity Input Failure 50
Informational 49
Invalid Unit Configuration 50
Latching 48
Local Fan Mode Failure 50
Local Setpoint Failure 50
Low Coil Temp Detection 49
Maintenance (filter change) 49
Manual 48
Nonlatching 48
Normal 50
Outdoor Air Temp Failure 50
Smart reset 49
Table 49
Types 48
Zone Temp Failure 49
Dimensional diagram 7
Dimensions 6
Failure diagnostic 50
Low limit diagnostic 49
Discharge air temperature input 16
Discharge air temperature low
limit 42
Discharge air tempering 33
DX cooling
Operation 39
Troubleshooting 53
E
Economizing 16, 38
55
Index
Electric heat
Operation 39
Troubleshooting 53
Diagnostic 49
Input 16
Sampling function 35
Equipment supported 6, 13, 18
Exhaust control 35
F
Fan
Exhaust 35
Mode input 15
Operation 35
Supply 35
Troubleshooting 51
Fan coils 6, 18
Fan off delay 41
Fan status
Input 14
Switching devices 9
Unit protection 41
Filter-maintenance timer 41
Four-pipe operation 37
Free cooling, <Emphasis>see
Economizing
Freeze avoidance 16, 41
Freeze-protection switch 9, 14
G
Generic
Binary input 14
Binary output 49
Temperature input 16
Generic AIP failure diagnostic 50
Generic binary input 14
Generic binary output 19
Generic temperature failure
diagnostic 50
H
Heating or cooling mode 34
Humidity
Input failure diagnostic 50
Measurement input 17
Zone sensor 17
Hydronic cooling 18
I
Informational diagnostics 49
56
Input/output functions 1330

Input/output terminal wiring 10
Invalid unit configuration
diagnostic 50
Isolation valve operation 39
L
LEDs
General 43
Interpreting green (status) 47
Interpreting red (service) 47
Interpreting yellow
(communications) 48
Location 43
Local fan mode input failure
diagnostic 50
Local setpoint failure diagnostic 50
Local setpoint input 15
LonTalk communication
Description 6
Termination resistors 11
Wiring and addressing 11
LonTalk protocol, <Emphasis>see
LonTalk communication
Diagnostic 14, 49
Input 14
M
Modulating outdoor/return air
dampers 37
Modulating valves
Calibration 36
Operation 36
Morning cool-down 34
Morning warm-up 34
Mounting
Cover 12
Diagram 12
Location 12
Operating environment 12
Procedures 12
N
National Electrical Code 10, 11
Neuron IDs
Description 11
Location of label 43
O
Occupancy
Switch 14
Switching devices 9
Occupancy input 14
Occupancy modes 31
General 31
Occupied 32
Occupied bypass 32
Occupied standby 32
Unoccupied 32
Operating environment 12
Outdoor air damper
Troubleshooting 53
Failure diagnostic 50
Input 16
Outdoor air temperature input 16
Outdoor/return air dampers 37
Output devices 9
Overriding binary outputs 19
General 43
P
Peer-to-peer communication 40
Power transformers 8, 10
Power wiring 10
Power-up sequence 31
Product description 6
Protection strategies, <Emphasis>see
R
Random start 31
Rover service tool
Adding a device 47
Configuring the controller 6
Identifying a device 47
User guide 6
Verifying LonTalk
communication 47
Verifying PCMCIA
communications 47
S
Sensor
Humidity 40
Sensors
Application-specific 17
CO2 9, 17
Table of options 9
Water and duct temperature 8
Zone humidity 9, 17
Zone temperature 9
Sequence of operations 3142
CNT-SVX07D-EN
Index
ASHRAE Cycle 1 38
ASHRAE Cycle 2 38
Baseboard heat 39
Dehumidification 40
limit 42
DX cooling 39
Economizing 38
Electric heat 39
Exhaust control 35
Face-and-bypass damper 39
Fan off delay 41
Fan operation 35
Fan status 41
Freeze avoidance 41
Heating/cooling mode 34
Isolation valve 39
Modulating-valve calibration 36
Modulating-valve operation 36
Morning cool-down 34
Morning warm-up 34
Occupancy modes 31
Outdoor/return air 37
Peer-to-peer communication 40
Power-up sequence 31
Random start 31
Smart reset 41
Timed override control 32
Two-pipe operation 37
Two-position damper
control 39
Two-position valve
operation 36
Unit protection strategies 40
Valves 36
Zone temperature control 33
Service pin button 43, 47
Smart reset
Diagnostic 41, 49
Unit protection 41
Specifications
AC power wiring 10
Clearances 7
Dimensional diagram 7
Dimensions 6
Input/output terminal wiring 10
LonTalk communication wiring
and addressing 11
CNT-SVX07D-EN
Storage environment 6
Transformers 11
Status indicators for operation and
communication
Diagnostics 48
General 43
Green (status) LEDs 47
LEDs 43
Red (service) LEDs 47
Service pin button 47
Test button 43
Yellow (communication)
LEDs 48
Storage environment 6
Switching devices
Condensate overflow 9, 14
Current sensing 9
Fan status 9
Freeze protection 9, 14
Low-coil-temperature 9
Occupancy 9, 14
T
Temperature sensors
Table of options 9
Water and duct 8
Zone 9
Termination resistors 11
Test button 4344
Timeclock 14
Timed override control 32
Transformers 8, 10, 11
Troubleshooting
DX cooling 53
Electric heat failure 53
Fans 51
Outdoor air damper 53
Valves 52
Two-position damper control 39
Two-position valve operation 36
Types of diagnostics 48
U
UL, <Emphasis>see Agency listing/
compliance
Condensate overflow 41
limit 42
Fan off delay 41
Fan status 41
Freeze avoidance 41
Low-coil-temperature
protection 41
Smart reset 41
Unit ventilators 6, 18
Universal 420 mA 17
V
Valves
Actuators 9
Calibration of modulating 36
General operation 36
Isolation-valve operation 36
Operation of modulating 36
Operation of two-position 36
Supported applications 6, 18,
36
Tri-state modulating 6, 18, 36
Troubleshooting 52
Two-position 6, 18
W
Water and duct temperature
sensors 8
Wiring
BAS communication 11
Compliance with National
Electrical Code 10, 11
Input/output terminals 10
LonTalk communication 11
Minimum requirements 19
Requirements and options 19
30
Wiring diagrams 1930
Electric heat unit 27
Electric heat unit with DX
cooling 26
Four-pipe heating/cooling unit
with auto changeover 24
Four-pipe heating/cooling unit
with face-and-bypass
damper 30
Four-pipe hydronic heating/
cooling unit 23
Two-pipe heating unit with DX
cooling 25
Two-pipe heating/cooling unit
with face-and-bypass
damper 29
57
Index
Two-pipe hydronic heating/

cooling unit with auto
changeover 22
Two-pipe hydronic-cooling
unit 20
Two-pipe hydronic-heating
unit 21
Z
Zone humidity
Sensor 9
Zone temperature
Input 15
Sensors 9
Zone temperature control 33
Zone temperature failure
diagnostic 49
58
CNT-SVX07D-EN
Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the
leader in creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad
portfolio of advanced controls and HVAC systems, comprehensive building services, and parts.
For more information, visit www.Trane.com.
Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.
2010 Trane All rights reserved
CNT-SVX07D-EN 08 Nov 2010
Supersedes CNT-SVX07C-EN (01 Apr 2005)

Manual Trane ZN521

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Installation and

Tracer ZN521 Zone Controller

All rights reserved

Warnings, Cautions, and Notices

WARNING: Indicates a potentially hazardous situation which, if not avoided,

CAUTION: Indicates a potentially hazardous situation which, if not avoided,

Doc Number (Variable)

General wiring information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mounting the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Input/output functions and wiring for typical applications . . . . . . . . . . . . . . . . . 13

Wiring requirements and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Timed override control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Discharge air tempering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Modulating outdoor/return air dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Two-position control of a modulating outdoor air damper . . . . . . . . . . . . . 39

Status indicators for operation and communication . . . . . . . . . . . . . . . . . . . . . . 43

Overview and specifications

The Tracer ZN521 can be configured to control:

Tri-state modulating or two-position valves

Tri-state modulating dampers:

DX cooling (single stage)

Electric heat (two stages)

Temperature: 40 to 185F (40 to 85C)

Relative humidity: 595%, noncondensing

Height: 5.375 in. (137 mm)

Width: 6.875 in. (175 mm)

Depth: 2 in. (51 mm)

Metal-cover model dimensions

Height: 9.0 in (25 mm)

Width: 10.37in. (263 mm)

Depth: 2.25 in. (58 mm)

Overview and specifications

Front: 4.0 in. (102 mm)

Each side: 1.0 in. (25 mm)

Top and bottom: 4.0 in. (102 mm)

Metal-cover model (see Figure 2 on page 8)

Front: 24.0 in. (610 mm)

Each side: 2.0 in. (51 mm)

Top and bottom: 1.0 in. (25 mm)

Figure 1. Plastic-cover model dimensions and clearances

5.625 in (143 mm)

2 in. (51 mm)

Overview and specifications

Figure 2. Metal-cover model dimensions and clearances

Water, duct, and outdoor-air temperature sensors

Overview and specifications

Binary input switching devices

Zone temperature sensors

Tracer zone temperature sensor options

Zone humidity sensor

General wiring information

AC power to the controller

Communication-link wiring, if the controller is to communicate with a building automation

Input/output terminal wiring

Analog input wiring must not exceed 300 ft (100 m).

Do not share 24 Vac between controllers.

General wiring information

Figure 3. Connecting ac power wires to the controller

Communication-link wiring and addressing

22 AWG Level 4 unshielded communications wire recommended for most Comm5