Honeywell PUL1012S User's Manual
Contents
1. DECLUTCH BUTTON M23568 Fig 1 Series 60 Floating Actuator IMPORTANT Mount actuator flush with damper housing or add a spacer between the actuator mounting surface and damper box housing SPYDER LON PROGRAMMABLE VAV UNITARY CONTROLLERS DAMPER SHAFT ROTATES CLOCKWISE TO OPEN M23569 Fig 2 Damper with 90 degree CW rotation to open Before Mounting Actuator onto Damper Shaft PVLOO00AS PVL4022AS and PVL6436AS Tools required Phillips 2 screwdriver end limit set screw adjustment 8mm wrench centering clamp Before mounting the actuator onto the VAV box damper shaft determine the following 1 Determine the damper shaft diameter It must be between 3 8 in to 1 2 in 10 to 13 mm 2 Determine the length of the damper shaft If the length of the VAV box damper shaft is less than 1 9 16 in 40 mm the actuator cannot be used 3 Determine the direction the damper shaft rotates to open the damper CW or CCW see Fig 3 Typically there is an etched line on the end of the damper shaft that indicates the position of the damper In Fig 2 the indicator shows the damper open in a CW direction 4 Determine the damper full opening angle 45 60 or 90 degrees In Fig 2 the damper is open to its full open position of 90 degrees TYPE A DAMPER AIR vy FLOW 7 a gt CW TO OPEN CCW TO CLOSE TYPE B DAMPER S AIR ax FLOW S pa M2067B2. 5 Pull on each wire in all terminals to check for good mechanical connection 41 STRIP 1 2 IN 13 MM FROM WIRES TO 1 2 BE ATTACHED AT 13 ONE TERMINAL 2 TWIST WIRES TOGETHER WITH PLIERS A MINIMUM OF THREE TURNS 3 CUT TWISTED END OF WIRES TO 3 16 IN 5 MM BEFORE INSERTING INTO TERMINAL AND TIGHTENING SCREW THEN PULL ON EACH WIRE IN ALL TERMINALS TO CHECK FOR GOOD MECHANICAL CONNECTION MIZO Fig 13 Attaching two or more wires at terminal blocks Controller Replacement PVLO000AS PVL4022AS and PVL6436AS For PVLOOOOAS PVL4022AS and PVL6436AS controllers which are hard wired to an actuator perform the following actions to replace the complete assembly controller and actuator 1 Remove all power from the controller 2 Remove the two air flow pickup connections from the pressure sensor 3 Remove the terminal blocks 4 Remove the old controller and actuator assembly from its mounting Loosen the two bolts on the actuator clamp to release the actuator from the shaft Remove the controller s mounting screws e Gently pull the controller and actuator assembly straight out until the assembly is clear of the actuator shaft 62 0287 03 SPYDER LON PROGRAMMABLE VAV UNITARY CONTROLLERS 5 Mount the new controller and actuator assembly see Installation on page 2 6 Reconnect the two air flow pickup tubes to the pressure sensor see Piping PVLOOOOAS PVL4022AS PVL4024NS
3. PVL4022AS VAV 4a 0 2 2 YES YES PVL4024NS VAV 4a 0 2 4 YES NO PVL6436AS VAV 6 4 3 6 YES YES PVL6438NS VAV 6 4 3 8 YES NO a One Universal Input UI 1 is user selectable as a fast digital pulse meter Each controller communicates via the 78 kbps Echelon LONWorRks Network using the FTT 10A LONWoRKS interface and is LONMARK compliant Controllers are field mountable to either a panel or a DIN rail 62 0287 03 SPYDER LON PROGRAMMABLE VAV UNITARY CONTROLLERS SPECIFICATIONS General Specifications Rated Voltage 20 30 Vac 50 60 Hz Power Consumption 100 VA for controller and all connected loads including the actuator on models PVLOOOOAS PVL4022AS and PVL6436AS Controller Only Load 20 VA maximum models PUL1012S PUL4024S PUL6438S PVL4024NS and PVL6438NS Controller and Actuator Load 21 VA maximum models PVLOOOOAS PVL4022AS and PVL6436AS External Sensors Power Output 20 Vdc 10 75 mA maximum VAV Operating amp Storage Temperature Ambient Rating models PVLOOO0AS PVL4022AS PVL4024NS PVL6436AS and PVL6438NS Minimum 32 F 0 C Maximum 122 F 50 C Unitary Operating amp Storage Temperature Ambient Rating models PUL1012S PUL4024S and PUL6438S Minimum 40 F 40 C Maximum 150 F 65 5 C Relative Humidity 5 to 95 non condensing LED Provides status for normal operation controller down load process alarms manual mode and error conditions BEFORE
4. PVL6436AS and PVL6438NS on page 5 7 Replace the terminal blocks e Insert each terminal block onto its alignment pins e Press straight down to firmly seat it e Repeat for each terminal block 8 Restore power to the controller 9 Perform checkout Controller Replacement PVL4024NS and PVL6438NS Perform the following to replace the PV4024NS and PVL6438NS controllers 1 Remove all power from the controller 2 Remove the two air flow pickup connections from the pressure sensor 3 Remove the terminal blocks 4 Remove the old controller from its mounting IMPORTANT FOR CONTROLLERS MOUNTED TO A DIN RAIL 1 Push straight up from the bottom to release the top pins 2 Rotate the top of the controller outwards to release the bottom flex connectors see Fig 8 on page 5 5 Mount the new controller e see Installation on page 2 6 Reconnect the two air flow pickup tubes to the pressure sensor see Piping PVLOOOOAS PVL4022AS PVL4024NS PVL6436AS and PVL6438NS on page 5 7 Replace the terminal blocks e Insert each terminal block onto its alignment pins e Press straight down to firmly seat it e Repeat for each terminal block 8 Restore power to the controller 9 Perform checkout Controller Replacement PUL1012S PUL4024S and PUL6438S Perform the following to replace the PUL1012S PUL4024S and PUL6438S controllers 1 Remove all power from the controller 2 Remove the terminal b
5. wiring throughout the installation CONNECT POWER TO TERMINALS 1 AND 2 GROUND TERMINAL 3 TRANSFORMER OUTPUT DEVICE POWER M23557A Fig 10 Power wiring details for one controller per transformer CONNECT POWER TO TERMINALS 1 AND 2 11111111112 12345678 901234567890 TRANSFORMER GROUND TERMINAL 3 LINE VOLTAGE i GREATER i A 777 i OUTPUT THAN 150 VAC EARTH DEVICE GROUND POWER A IF THE CONTROLLER IS USED IN UL 1995 EQUIPMENT AND THE PRIMARY POWER IS MORE THAN 150 VOLTS GROUND 24 VAC COM SIDE OF TRANSFORMER SECONDARY ipasaan Fig 11 Transformer power wiring details for one controller used in UL 1995 equipment U S only IMPORTANT More than one controller can be powered by a single If the controller is used on Heating and Cooling Equipment UL 1995 U S only and the transformer primary power is more than 150 volts connect terminal 2 the 24 Vac common 24 VAC COM terminal to earth ground see Fig 11 For these applications only one controller can be powered by each transformer NOTES Unswitched 24 Vac power wiring can be run in the same conduit as the LONWoRKS cable 62 0287 03 6 transformer Fig 12 shows power wiring details for multiple controllers NOTE Controller configurations are not necessarily limited to three devices but the total power draw including accessories cannot exceed 100 VA when powered by the same tran
6. CCW TO OPEN CW TO CLOSE Fig 3 Determining the rotation direction CW or CCW for damper opening Mounting Actuator onto Damper Shaft PVLOOOOAS PVL4022AS and PVL6436AS The unit is shipped with the actuator set to rotate open in the clockwise CW direction to a full 95 degrees The extra 5 degrees ensures a full opening range for a 90 degree damper The installation procedure varies depending on the damper opening direction and angle 1 Ifthe damper rotates clockwise CW to open and the angle of the damper open to closed is 90 degrees a Manually open the damper fully rotate clockwise b Using the Declutch button rotate the universal shaft adapter fully clockwise c Mount the actuator to the VAV damper box and shaft d Tighten the two bolts on the centering clamp 8 mm wrench 70 8 88 5 Ib in B 10 Nm torque When the actuator closes the damper rotates CCW 90 degrees to fully close 2 Ifthe damper rotates clockwise CW to open and the angle of the damper open to closed is 45 or 60 degrees a Manually open the damper fully rotate clockwise b The actuator is shipped with the mechanical end limits set at 95 degrees Adjust the two mechanical end limit set screws to provide the desired amount of rotation Adjust the two set screws closer together to reduce the rotation travel c Tighten the two mechanical end limit screws Phillips 2 screwdriver 26 5 31 Ib in 3 0 3 5 Nm torque d Using the De
7. PROGRAMMABLE VAV UNITARY CONTROLLERS Panel Mounting The controller enclosure is constructed of a plastic base plate and a plastic factory snap on cover NOTE The controller is designed so that the cover does not need to be removed from the base plate for either mounting or wiring The controller mounts using four screws inserted through the corners of the base plate Fasten securely with four No 6 or No 8 machine or sheet metal screws The controller can be mounted in any orientation Ventilation openings are designed into the cover to allow proper heat dissipation regardless of the mounting orientation DIN Rail Mounting PUL1012S PUL4024S PUL6438S PVL4024NS and PVL6438NS To mount the PUL1012S PUL4024S PUL6438S PVL4024NS or PVL6438NS controller on a DIN rail standard EN50022 1 3 8 in x 9 32 in 7 5 mm x 35 mm J refer to ra 8 and perform the following steps Holding the controller with its top tilted in towards the DIN rail hook the two top tabs on the back of the con troller onto the top of the DIN rail 2 Push down and in to snap the two bottom flex connec tors of the controller onto the DIN rail BOTTOM FLEX CONNECTORS M16815 Fig 8 Controller DIN rail mounting models PUL1012S PUL4024S PUL6438S PVL4024NS and PVL6438NS IMPORTANT To remove the controller from the DIN rail perform the following 1 Push straight up from the bottom to release the top tabs 2 Rotate the top of the con
8. Honeywell Spyder Lon Programmable VAV Unitary Controllers INSTALLATION INSTRUCTIONS PRODUCT DESCRIPTION The PUL1012S PUL4024S PUL6438S PVLOOOOAS PVL4022AS PVL4024NS PVL6436AS and PVL6438NS controllers are part of the Excel 10 product line family The eight controllers are Free Topology Transceiver FTT LONMARK compliant devices designed to control HVAC equipment These controllers provide many options and advanced system features that allow state of the art commercial building control Each controller is programmable and configurable through software These controllers are for use in VAV Variable Air Volume and Unitary HVAC control applications Each controller contains a host micro controller to run the main HVAC application and a second micro controller for LONWoRKS network communications Each controller has flexible universal inputs for external sensors digital inputs and a combination of analog and digital Triac outputs The eight models are described in Table 1 The photo to the left is the model PVL6436AS which includes the actuator Table 1 Controller configurations Velocity Universal Digital Analog Digital Pressure Series 60 Controller Programmable Inputs Inputs Outputs Outputs Sensor Floating Model Type Ul Dl AO DO Microbridge Actuator PUL1012S Unitary 4a 0 1 2 NO NO PUL4024S Unitary 4a 0 2 4 NO NO PUL6438S Unitary 6 4 3 8 NO NO PVLOOOOAS VAV 0 0 0 0 YES YES
9. INSTALLATION The controller is available in eight models see Table 1 Review the power input and output specifications on page 2 before installing the controller Hardware driven by Triac outputs must have a minimum current draw when energized of 25 mA and a maximum current draw of 500 mA Hardware driven by the analog current outputs must have a maximum resistance of 550 Ohms resulting in a maximum voltage of 11 volts when driven at 20 mA If resistance exceeds 550 Ohms voltages up to 18 Vdc are possible at the analog output terminal A WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect power supply before beginning wiring or making wiring connections to prevent electrical shock or equipment damage INSTALLATION The controller must be mounted in a position that allows clearance for wiring servicing removal connection of the LonWorks Bus Jack and access to the Neuron Service Pin The controller may be mounted in any orientation IMPORTANT Avoid mounting in areas where acid fumes or other deteriorating vapors can attack the metal parts of the controller or in areas where escaping gas or other explosive vapors are present See Fig 4 Fig 7 on page 4 for mounting dimensions 62 0287 03 2 For PVLOOOOAS PVL4022AS and PVL6436AS models the actuator is mounted first and then the controller is mounted For the other models go to Mount Controlle
10. clutch button rotate the universal shaft adapter fully clockwise e Mount the actuator to the VAV damper box and shaft f Tighten the two bolts on the centering clamp 8 mm wrench 70 8 88 5 Ib in 8 10 Nm torque g When the actuator closes the damper rotates CCW either 45 or 60 degrees to fully close 3 If the damper rotates counterclockwise CCW to open and the angle of the damper open to closed is 90 degrees a Manually open the damper fully rotate counter clockwise b Using the Declutch button rotate the universal shaft adapter fully counterclockwise c Mount the actuator to the damper box and shaft d Tighten the two bolts on the centering clamp 8 mm wrench 70 8 88 5 Ib in 8 10 Nm torque When the actuator closes the damper rotates CW 90 degrees to fully close 4 Ifthe damper rotates counterclockwise CCW to open and the angle of the damper open to closed is 45 or 60 degrees a Manually open the damper fully rotate counter clockwise b The actuator is shipped with the mechanical end limits set at 95 degrees Adjust the two mechanical end limit set screws to provide the desired amount of rotation Adjust the two set screws closer together to reduce the rotation travel c Tighten the two mechanical end limit screws Phillips 2 screwdriver 26 5 31 Ib in 3 0 3 5 Nm torque d Using the Declutch button rotate the universal shaft adapter fully counter clockwise Mount the actuato
11. ee Fig 12 on page 7 _ Allloads on the controller must be powered by the same transformer that powers the controller itself A controller can use separate transformers for controller power and output power Keep the earth ground connection terminal 3 wire run as short as possible Do not connect the universal input COM terminals analog output COM terminals or the digital input output COM terminals to earth ground Refer to Fig 10 Fig 12 for wiring examples The 24 Vac power from an energy limited Class II power source must be provided to the controller To conform to Class ll restrictions U S only the transformer must not be larger than 100 VA Fig 10 depicts a single controller using one transformer IMPORTANT Power must be off prior to connecting to or removing connections from the 24 Vac power 24 Vac 24 Vac COM earth ground EGND and 20 Vdc power 20 Vdc terminals IMPORTANT Use the heaviest gauge wire available up to 14 AWG 2 0 sq mm with a minimum of 18 AWG 1 0 sq mm for all power and earth ground wiring Screw type terminal blocks are designed to accept up to one 14 AWG 2 0 sq mm conductor or up to two 18 AWG 1 0 sq mm conductors More than two wires that are 18 AWG 2 0 sq mm can be con nected with a wire nut Include a pigtail with this wire group and attach the pigtail to the terminal block Maintain at least a 3 in 7 6 cm separation between Triac outputs and LONWoRKS
12. locks 3 Remove the old controller from its mounting IMPORTANT FOR CONTROLLERS MOUNTED TO A DIN RAIL 1 Push straight up from the bottom to release the top pins 2 Rotate the top of the controller outwards to release the bottom flex connectors see Fig 8 on page 5 Mount the new controller see Installation on page 2 Replace the terminal blocks e Insert each terminal block onto its alignment pins e Press straight down to firmly seat it e Repeat for each terminal block 6 Restore power to the controller 7 Perform checkout oe LON LONTALK LONWoRKS and NEURON are registered trademarks of Echelon Corporation LONMARK and the LonMark Logo are trademarks of the LonMark Association NIAGARA FRAMEWORK and the Niagara framework logo are registered trademarks of Tridium Inc Automation and Control Solutions Honeywell International Inc 1985 Douglas Drive North Golden Valley MN 55422 customer honeywell com 35 Dynamic Drive U S Registered Trademark Toronto Ontario M1V 4Z9 Honeywell Limited Honeywell Limit e Honeywell Printed in U S A on recycled 2009 Honeywell International Inc amp paper containing at least 10 62 0287 03 K K 02 09 post consumer paper fibers
13. lt St 4 1 8 105 4 1 8 105 Se ee peocegpeceed TEVATLT 22222 TUUVT TT 22228 La 345678901234 345678901234 U 6 1 4 6 1 4 159 159 5 7 8 O 5 7 8 O 149 149 EE i oe i arane 7o00 ae h 23456789019 ae jeeececieciooo jeeecec ociooee 3 16 4 5 PANEL MOUNTING HOLE 4X NOTE CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION M28649 Fig 5 Panel mounting controller dimensions in inches mm for PUL1012S PUL4024S and PVL4024NS only PUL4024S and PVL4024NS shown 8 9 32 211 1 1576 4 1 8 49 105 NO 27 32 200celee0000 2 o 21 eeee OO f H 111711111112 TE lo A 901234567890 U 7 6 1 4 6 9 32 149 12345678 8 eeee b 9 pesooojoej DEPTH IS 3 16 4 5 PANEL 2 1 4 57 MOUNTING HOLE 4X NOTE CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION iizosia Fig 6 Panel mounting controller and actuator dimensions in inches mm for PVLOOO0AS and PVL4022AS only PVL4022AS shown PUL6438S 5 29 64 139 DEPTH IS 2 1 4 57 M23589B Fig 7 Panel mounting controller dimensions in inches mm for PUL6438S and PVL6438NS only 62 0287 03 4 SPYDER LON
14. r on page 4 to begin the installation Mount Actuator onto Damper Shaft PVLOOO0AS PVL4022AS and PVL6436AS PVLOOOOAS PVL4022AS and PVL6436AS controllers include the direct coupled actuator with Declutch mechanism which is shipped hard wired to the controller The actuator mounts directly onto the VAV box damper shaft and has up to 44 Ib in 5 Nm torque 90 degree stroke and 90 second timing at 60 Hz The actuator is suitable for mounting onto a 3 8 to 1 2 in 10 to 13 mm square or round VAV box damper shaft The minimum VAV box damper shaft length is 1 9 16 in 40 mm The two mechanical end limit set screws control the amount of rotation from 12 to 95 These set screws must be securely fastened in place To ensure tight closing of the damper the shaft adapter has a total rotation stroke of 95 see Fig 1 NOTE The actuator is shipped with the mechanical end limit set screws set to 95 degrees of rotation Adjust the two set screws closer together to reduce the rotation travel Each hash mark indicator on the bracket represents approximately 6 5 of rotation per side NOTE The Declutch button when pressed allows you to rotate the universal shaft adapter see Fig 1 IMPORTANT Determine the damper rotation and opening angle prior to installation See Fig 2 and Fig 3 on page 3 for examples UNIVERSAL SHAFT CLAMPING BOLTS 2 UNIVERSAL SHAFT ADAPTER MECHANICAL END LIMIT SET SCREWS 2
15. r to the VAV damper box and shaft Tighten the two bolts on the centering clamp 8 mm wrench 70 8 88 5 Ib in 8 10 Nm torque g When the actuator closes the damper rotates CW either 45 or 60 degrees to fully close mo 62 0287 03 SPYDER LON PROGRAMMABLE VAV UNITARY CONTROLLERS Mount Controller NOTE The controller may be wired before mounting to a panel or DIN rail Terminal blocks are used to make all wiring connections to the controller Attach all wiring to the appropriate terminal blocks see Wiring on page 5 See Fig 4 to Fig 7 for panel mounting dimensions See Fig 8 on page 5 for DIN rail mounting lt 10 5 16 262 lt 8 5 16 211 1 55 64 a 6 29 64 164 e 47 gt I 22222222233333333334 wi 5 3 4 o 12345678901234567890 E We A 146 716 11 g 6 17 64 159 5 3 64 128 nil 11111111 12345678 901234567 PANEL MOUNTING HOLE DEPTH IS 4X 3 16 IN 4 5 2 1 4 57 NOTE CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION M28647 Fig 4 Panel mounting controller and actuator dimensions in inches mm for PVL6436AS only PANEL MOUNTING HOLE 4X 29 64 IN 12 PVL6438NS 5 3 64 5 29 64 139 ida lt 6 29 64 164 _ gt lt lt 6 27 32 174 gt NOTE CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION DEPTH IS 2 1 4 57 ji 4 13 16 122 4 13 16 122
16. sformer U S only For power wiring recommendations see Wiring on page 5 SPYDER LON PROGRAMMABLE VAV UNITARY CONTROLLERS CONNECT POWER TO TERMINALS 1 AND 2 120 240 VAC TRANSFORMER OUTPUT DEVICE POWER M23559A Fig 12 Power wiring details for two or more controllers per transformer Wiring Method A WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect power supply before beginning wiring or making wiring connections to prevent electrical shock or equipment damage NOTE When attaching two or more wires to the same termi nal other than 14 AWG 2 0 sq mm be sure to twist them together Deviation from this rule can result in improper electrical contact see Fig 13 Each terminal can accommodate the following gauges of wire Single wire from 22 AWG to 14 AWG solid or stranded Multiple wires up to two 18 AWG stranded with 1 4 watt wire wound resistor Prepare wiring for the terminal blocks as follows Strip 1 2 in 13 mm insulation from the conductor 2 Cuta single wire to 3 16 in 5 mm Insert the wire in the required terminal location and tighten the screw 3 If two or more wires are being inserted into one terminal location twist the wires together a minimum of three turns before inserting them see Fig 13 4 Cut the twisted end of the wires to 3 16 in 5 mm before inserting them into the terminal and tightening the screw
17. tor or use diagonal cutters to cut the edge of the tubing attached to the connector Never remove by pulling at an angle AIR FLOW PICKUP i CONNECTOR SSN TUBING RESTRICTOR RESTRICTOR PORT PORT 11111112 901234507890 12345678 M23556A Fig 9 Air flow pickup connections PVLOO000AS PVL4022AS PVL4024NS PVL6436AS and PVL6438NS Wiring All wiring must comply with applicable electrical codes and ordinances or as specified on installation wiring diagrams Controller wiring is terminated to the screw terminal blocks located on the top and the bottom of the device A WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect power supply before beginning wiring or making wiring connections to prevent electrical shock or equipment damage 62 0287 03 SPYDER LON PROGRAMMABLE VAV UNITARY CONTROLLERS NOTES For multiple controllers operating from a single transformer the same side of the transformer sec ondary must be connected to the same power input terminal in each controller Controller config urations will not necessarily be limited to three devices but the total power draw including accessories cannot exceed 100 VA when pow ered by the same transformer U S only For power and wiring recommendations see Wiring on page 5 The earth ground terminal terminal 3 must be connected to a verified earth ground for each controller in the group s
18. troller out towards you and pull the controller down and away from the DIN rail to release the bottom flex connectors Piping PVLOQ00AS PVL4022AS PVL4024NS PVL6436AS and PVL6438NS Air flow Pickup For PVLOOOOAS PVL4022AS PVL4024NS PVL6436AS and PVL6438NS connect the air flow pickup to the two restrictor ports on the controller see Fig 9 NOTES Use 1 4 inch 6 mm outside diameter with a 0 040 in 1 mm wall thickness plenum rated 1219 FR 94V 2 tubing Always use a fresh cut on the end of the tubing that connects to the air flow pickups and the restrictor ports on the controller Connect the high pressure or upstream tube to the plastic restrictor port labeled and the low pressure or downstream tube to the restrictor port labeled See labeling in Fig 9 When twin tubing is used from the pickup split the pickup tubing a short length to accommodate the connections NOTES If controllers are mounted in unusually dusty or dirty environments an inline 5 micron disposable air filter use 5 micron filters compatible with pneumatic controls is recommended for the high pressure line marked as connected to the air flow pickup The tubing from the air flow pickup to the control ler should not exceed three feet 0 914 m Any length greater than this will degrade the flow sensing accuracy Use caution when removing tubing from a con nector Always pull straight away from the con nec
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