Honeywell Spyder PUL1012S, Spyder PVL4022AS Manual

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Honeywell Spyder PUL1012S, Spyder PVL4022AS Manual | Manualzz

Spyder® Lon

Programmable, VAV/Unitary Controllers

PRODUCT DESCRIPTION

The PUL1012S, PUL4024S, PUL6438S, PVL0000AS,

PVL4022AS, PVL4024NS, PVL6436AS, and PVL6438NS controllers are part of the Spyder family. The eight controllers are Free Topology Transceiver (FTT) L

ON

M

ARK

®

-compliant devices designed to control HVAC equipment. These controllers provide many options and advanced system

PRODUCT DATA

features that allow state-of-the-art commercial building control. Each controller is programmable and configurable through software.

The Spyder Lon controllers require the Spyder Programmable

Feature to be licensed in the WEBpro workbench tool and the

WEBS AX JACE Controller for programming and downloading. The eight Spyder Lon Models are also available as Individually Licensed Controllers (ILC). The ILC versions are identical in design and capability in every detail except for the licensing. The Individual Licensing of the Spyder ILCs

(The License is built in) allows them to be programmed and downloaded with any brand of the Niagara Workbench or

JACE controller. The Spyder ILCs are identified with a suffix on the Part Number of -ILC. Example: PUL6438S-ILC follows all the same Installation Instructions information as the

PUL6438S.

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 L

ON

W

ORKS

® 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 of the model

PVL6436AS, which includes the actuator.

Contents

Product Description ..........................................................

1

Specifications ...................................................................

3

Installation ........................................................................

4

Checkout .......................................................................... 21

Controller Replacement .................................................... 22

63-2685-03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

Table 1. Controller configurations.

Controller

Model

PUL1012S

PUL4024S

PUL6438S

PVL0000AS

PVL4022AS

PVL4024NS

PVL6436AS

PVL6438NS

Programmable

Type

Unitary

Unitary

Unitary

VAV

VAV

VAV

VAV

VAV

Universal

Inputs

(UI)

1 a

4 a

6

0

4 a

4 a

6

6

Digital

Inputs

(DI)

0

0

4

0

0

0

4

4

Analog

Outputs

(AO)

1

2

3

0

2

2

3

3

Digital

Outputs

(DO)

2

4

8

0

2

4

6

8

Velocity

Pressure

Sensor

(Microbridge)

NO

NO

NO

YES

YES

YES

YES

YES

Series 60

Floating

Actuator

NO

NO

NO

YES

YES

NO

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® L

ON

W

ORKS

® Network, using the FTT-10A L

ON

W

ORKS

® interface, and is

L ON M ARK ® compliant.

Controllers are field-mountable to either a panel or a DIN rail.

ORDERING INFORMATION

When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the

TRADELINE® Catalog or price sheets for complete ordering number.

If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:

1.

Your local Honeywell Automation and Control Products Sales Office (check white pages of your phone directory).

2.

Honeywell Customer Care

1885 Douglas Drive North

Minneapolis, Minnesota 55422-4386

In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Toronto, Ontario M1V 4Z9.

International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,

Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.

63-2685—03 2

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 PVL0000AS, PVL4022AS, and

PVL6436AS)

Controller Only Load: 5 VA maximum; models PUL1012S,

PUL4024S, PUL6438S, PVL4024NS, and PVL6438NS.

Controller and Actuator Load: 9 VA maximum; models

PVL0000AS, PVL4022AS, and PVL6436AS

External Sensors Power Output: 20 Vdc ±10% @ 75 mA maximum

VAV Operating & Storage Temperature Ambient Rating

(models PVL0000AS, PVL4022AS, PVL4024NS,

PVL6436AS, and PVL6438NS):

Minimum 32 F (0 C); Maximum 122 F (50 C)

Unitary Operating & 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 download process, alarms, manual mode, and error conditions

Velocity Pressure Sensor (Models

PVL0000AS, PVL4022AS, PVL4024NS,

PVL6436AS, and PVL6438NS only)

Operating Range: 0 to 1.5 in. H

2

O (0 to 374 Pa)

Series 60 Floating Actuator (PVL0000AS,

PVL4022AS, and PVL6436AS)

Rotation Stroke: 95° ± 3° for CW or CCW opening dampers

Torque Rating: 44 lb-in. (5 Nm)

Run Time for 90° rotation: 90 seconds at 60 Hz

Operating Temperature: -4 F to 140 F (-20 to 60 C)

Real Time Clock

Operating Range: 24 hour, 365 day, multi-year calendar including day of week and configuration for automatic daylight savings time adjustment to occur at 2:00 a.m. local time on configured start and stop dates

Power Failure Backup: 24 hours at 32 to 100° F (0 to 38° C),

22 hours at 100 to 122° F (38 to 50° C)

Accuracy: ±1 minute per month at 77 F (25 C)

Digital Input (DI) Circuits

Voltage Rating: 0 to 30 Vdc open circuit

Input Type: Dry contact to detect open and closed circuit

Operating Range: Open circuit = False; Closed circuit = True

Resistance: Open circuit > 3,000 Ohms; Closed circuit < 500

Ohms

Digital Triac Output (DO) Circuits

Voltage Rating: 20 to 30 Vac @ 50/60Hz

Current Rating: 25 mA to 500 mA continuous, and

800 mA (AC rms) for 60 milliseconds

Analog Output (AO) Circuits

Analog outputs can be individually configured for current or voltage.

ANALOG CURRENT OUTPUTS:

Current Output Range: 4.0 to 20.0 mA

Output Load Resistance: 550 Ohms maximum

ANALOG VOLTAGE OUTPUTS:

Voltage Output Range: 0 to 10.0 Vdc

Maximum Output Current: 10.0 mA

Analog outputs may be configured as digital outputs and operate as follows:

– False (0%) produces 0 Vdc, (0 mA)

– True (100%) produces the maximum 11 Vdc, (22 mA)

Universal Input (UI) Circuits

See Table 2 for the UI circuit specifications.

Table 2. Universal input circuit specifications.

Input

Type

Room/Zone

Discharge Air

Outdoor Air

Temperature

Outdoor Air

Temperature

TR23

Setpoint

Potentiometer to

Sensor

NTC

Type

20K Ohm

C7031G

C7041F

PT1000 a a

(IEC751 3850)

500 Ohm

10,500 Ohm

Operating

Range

-40 F to 199 F

(-40 C to 93 C)

-40 F to 120 F

(-40 C to 49 C)

-40 F to 250 F

(-40 C to 121 C)

-40 F to 199 F

(-40 C to 93 C)

-4° DDC to +4° DDC

(-8° DDF to +7° DDF) or

50 F to 90 F

(10 C to 32 C)

100 Ohms to 100K Ohms

0–10 Vdc

Resistive Input Generic

Voltage

Input

Transducer,

Controller

Discrete Input Dry Contact

Pulse Input b closure

Open Circuit > 3000 Ohms

Closed Circuit < 3000 Ohms

Counter/Meter Max. frequency: 15 Hz

Min. pulse width: 20 ms

Max. chatter 5 ms a

C7031G and C7041F are recommended for use with these controllers, due to improved resolution and accuracy when compared to the PT1000.

b

One Universal Input (UI-1*) on the PUL1012S, PUL4024S,

PVL4022AS, and PVL4024NS is user selectable as a fast digital pulse meter.

3

BEFORE INSTALLATION

The controller is available in eight models (see Table 1).

Review the power, input, and output specifications on page 3

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.

63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

— 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.

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

(see Fig. 16 and Fig. 17 on page 14).

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. Fig. 4–Fig. 7 on page 6 for mounting dimensions.

For PVL0000AS, PVL4022AS, and PVL6436AS models, the actuator is mounted first and then the controller is mounted.

For the other models, go to “Mount Controller” on page 5 to

begin the installation.

Mount Actuator onto Damper Shaft

(PVL0000AS, PVL4022AS, and

PVL6436AS)

PVL0000AS, 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 lb-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).

NOTES:

1.

2.

The actuator is shipped with the mechanical endlimit 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.

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 3 for examples.

UNIVERSAL SHAFT

CLAMPING BOLTS (2)

UNIVERSAL

SHAFT ADAPTER

MECHANICAL

END LIMIT SET

SCREWS (2)

DECLUTCH

BUTTON

M23568

Fig. 1. Series 60 Floating Actuator.

DAMPER

DAMPER SHAFT

ROTATES

CLOCKWISE

TO OPEN M23569

Fig. 2. Damper with 90 degree CW rotation to open.

IMPORTANT

Mount actuator flush with damper housing or add a spacer between the actuator mounting surface and damper box housing.

Before Mounting Actuator onto Damper

Shaft (PVL0000AS, PVL4022AS, and

PVL6436AS)

Tools required:

— Phillips #2 screwdriver - end-limit set screw adjustment

— 8 mm wrench - centering clamp

63-2685—03 4

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

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. and 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’s 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

FLOW

AIR

FLOW

CW TO OPEN, CCW TO CLOSE

TYPE B DAMPER

M2067B CCW TO OPEN, CW TO CLOSE

Fig. 3. Determining the rotation direction (CW or CCW) for damper opening.

Mounting Actuator Onto Damper Shaft

(PVL0000AS, 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.

If the 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 lb-in. [8–10 Nm] torque).

When the actuator closes, the damper rotates CCW

90 degrees to fully close.

2.

If the 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 lb-in. [3.0–3.5 Nm] torque).

d. Using the Declutch 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 lb-in. [8–10 Nm] torque).

5 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 counterclockwise).

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 lb-in. [8–10 Nm] torque). When the actuator closes, the damper rotates CW

90 degrees to fully close.

4.

If the damper rotates counterclockwise to open, and the angle of the damper open-to-closed is 45 or 60 degrees: a. Manually open the damper fully (rotate counterclockwise).

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 lb-in. [3.0–3.5 Nm] torque).

d. Using the Declutch button, rotate the universal shaft adapter fully counterclockwise. 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 lb-in. [8–10 Nm] torque).

g. When the actuator closes, the damper rotates CW either 45 or 60 degrees to fully close.

IMPORTANT

Special precautions must be taken for dampers that open in a CCW direction. The actuator is shipped with its rotation direction set to CW to Open, which applies to the damper direction in steps 1 and 2 above. If the damper shaft rotates in the CCW direction to open, the controller software must be programmed to change the rotation to “Reverse to Open,” which applies to the damper direction in steps 3 and 4 above.

IMPORTANT

It is advisable to leave the dampers in an open position after installation to avoid the possibility of over-pressurizing the duct work on fan startup. Use the Declutch button (see Fig. 1 on page 4) to open the box damper on controllers that are powered down, to prevent over-pressurization in the duct work on fan startup. To Declutch, press and hold the button to disengage the motor. Turn the damper shaft until the damper is open and release the button. When power is restored to the controller, the controller synchronizes the damper actuator, so that the damper is in the correct position upon startup.

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 9).

See Fig. 4–Fig. 7 for panel mounting dimensions. See Fig. 8 on page 7 for DIN rail mounting.

63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

6-1/4

(159)5-7/8

(149)

4-1/8

(105)

8-9/32

(211) 1-15/16

(49)

5-3/4

(146)

5-3/64

(128)

27/32

(21)

6-9/32

(159)

1 2 3 4 5 6 7 8

3/16 (4.5) PANEL

MOUNTING HOLE (4X)

NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.

DEPTH IS

2-1/4 (57)

M28648

Fig. 4. Panel mounting - controller and actuator dimensions in inches (mm) for PVL0000AS and

PVL4022AS only (PVL4022AS shown).

10-5/16 (262)

8-5/16 (211)

6-29/64 (164)

1-55/64

(47)

5-3/4

(146)

1 2 3 4 5 6 7 8 0

3

7/16

(11)

6-17/64

(159)

5-3/64

(128)

1 2 3 4 5 6 7 8 9

1

2 3 4 5 6 7

PANEL MOUNTING HOLE

(4X) 3/16 IN. (4.5)

DEPTH IS

2-1/4 (57)

NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.

M28647

Fig. 5. Panel mounting - controller and actuator dimensions in inches (mm) for PVL6436AS only.

6-1/4

(159)

5-7/8

(149)

4-13/16 (122)

4-1/8 (105)

1 1 1 1 1 1 1 2 2 2 2 2

3 4 5 6 7 8 9 0 1 2 3 4

DEPTH IS 2-1/4 (57)

4-13/16 (122)

4-1/8 (105)

1 1 1 1 1 1 1 2 2 2 2 2

3 4 5 6 7 8 9 0 1 2 3 4

6-1/4

(159)

5-7/8

(149)

1 1

1 2 3 4 5 6 7 8 9 0 1 2

1 1

1 2 3 4 5 6 7 8 9 0 1 2

3/16 (4.5) PANEL MOUNTING HOLE (4X)

NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.

M28649

Fig. 6. Panel mounting - controller dimensions in inches

(mm) for PUL1012S, PUL4024S, and PVL4024NS only

(PUL4024S and PVL4024NS shown).

PANEL MOUNTING HOLE

(4X) 29/64 IN. (12)

PVL6438NS

1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 0

5-3/64

(128)

PUL6438S

2 2 2 2 2 2 3 3 3

5-29/64

(139)

5-29/64

(139)

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 0

6-29/64 (164)

6-27/32 (174)

NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.

DEPTH IS

2-1/4 (57)

6-29/64 (164)

6-27/32 (174)

M23589B

Fig. 7. Panel mounting - controller dimensions in inches (mm) for models PUL6438S and PVL6438NS only.

Panel Mounting

The controller enclosure is constructed of a plastic base plate

63-2685—03 6 and a plastic factory-snap-on cover.

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

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)], refer to Fig. 8 and perform the following steps:

1.

Holding the controller with its top tilted in towards the

DIN rail, hook the two top tabs on the back of the controller onto the top of the DIN rail.

2.

Push down and in to snap the two bottom flex connectors of the controller onto the DIN rail.

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 controller out towards you and pull the controller down and away from the DIN rail to release the bottom flex connectors.

TOP TABS

— 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 controller 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 connector. Always pull straight away from the connector 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

RESTRICTOR

PORT

Δ P

CONNECTOR

TUBING

RESTRICTOR

PORT

1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 0

DIN RAIL

BOTTOM FLEX

CONNECTORS M16815

Fig. 8. Controller DIN rail mounting (models PUL1012S,

PUL4024S, PUL6438S, PVL4024NS, and PVL6438NS).

Piping (PVL0000AS, PVL4022AS,

PVL4024NS, PVL6436AS, and

PVL6438NS)

Air flow Pickup

For PVL0000AS, PVL4022AS, PVL4024NS, PVL6436AS, and

PVL6438NS, connect the air flow pickup to the two restrictor ports on the controller (see Fig. 9).

NOTES:

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 0

M23556A

Fig. 9. Air flow pickup connections (PVL0000AS,

PVL4022AS, PVL4024NS, PVL6436AS, and PVL6438NS).

Power

Before wiring the controller, determine the input and output device requirements for each controller used in the system.

Select input and output devices compatible with the controller and the application. Consider the operating range, wiring requirements, and the environment conditions when selecting input/output devices. When selecting actuators for modulating applications consider using floating control. In direct digital control applications, floating actuators will generally provide control action equal to or better than an analog input actuator for lower cost.

Determine the location of controllers, sensors, actuators and other input/output devices and create wiring diagrams. Refer to

Fig. 19 to Fig. 25 beginning on page 16 for illustrations of typical controller wiring for various configurations.

7 63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

The application engineer must review the control job requirements. This includes the sequences of operation for the controller, and for the system as a whole. Usually, there are variables that must be passed between the controller and other

Spyder Lon controller(s) that are required for optimum systemwide operation. Typical examples are the TOD, Occ/Unocc signal, the outdoor air temperature, the demand limit control signal, and the smoke control mode signal.

It is important to understand these interrelationships early in the job engineering process, to ensure proper implementation when configuring the controllers. Refer to the controller

Application Guides.

Power Budget

A power budget must be calculated for each device to determine the required transformer size for proper operation. A power budget is simply the summing of the maximum power draw ratings (in VA) of all the devices to be controlled. This includes the controller itself and any devices powered from the controller, such as equipment actuators (ML6161 or other motors) and various contactors and transducers.

IMPORTANT

• If a controller is used on Heating and Cooling Equipment (UL 1995, U.S. only) and transformer primary power is more than 150 volts, connect the transformer secondary common to earth ground (see Fig. 12 on page 10).

• When multiple controllers operate from a single transformer, connect the same side of the transformer secondary to the same power input terminal in each device. The earth ground terminal (terminal 3) must be connected to a verified earth ground for each controller in the group (see Fig. 13 on page 11).

POWER BUDGET CALCULATION EXAMPLE

Table 3 is an example of a power budget calculation for typical

PVL0000AS, PVL4022AS, and PVL6436AS controllers. While the example is shown for only these models, the process is applicable for all controller models.

Table 3. Power budget calculation example.

Device

PVL0000AS,

PVL4022AS, and

PVL6436AS controllers (include

Series 60 Floating

Damper Actuator)

R8242A Contactor fan rating

VA

Information

9.0

21.0

D/X Stages

M6410A Steam

Heating Coil Valve

0.0

0.7

Obtained From

See “Specifications” on page 3.

TRADELINE

® inrush rating

Catalog

For example, assume cooling stage outputs are wired into a compressor control circuit and have no impact on the budget.

TRADELINE

®

0.32A 24 Vac

Catalog,

TOTAL 30.7

The system example above requires 30.7 VA of peak power.

Therefore, a 100 VA AT92A transformer could be used to power one controller of this type. Because the total peak power

63-2685—03 8 is less than 33 VA, this same transformer could be used to power three of these controllers and meet NEC Class 2 restrictions (no greater than 100 VA).

See Fig. 11–Fig. 13 beginning on page 10 for illustrations of controller power wiring. See Table 4 for VA ratings of various devices.

ML684

ML6161

ML6185

ML6464

ML6474

R6410A

R8242A

Table 4. VA ratings for transformer sizing.

Device

PVL0000AS,

PVL4022AS, and

PVL6436AS controllers and

Series 60 Floating

Damper Actuator

PUL1012S,

PUL4024S,

PUL6438S,

PVL4024NS, or

PVL6438NS

Description

Controller and Actuator

Controller

Versadrive Valve Actuator

Damper Actuator, 35 lb-in.

Damper Actuator SR 50 lb-in

Damper Actuator, 66 lb-in.

Damper Actuator, 132 lb-in.

Valve Actuator

Contactor

VA

9.0

5.0

12.0

2.2

12.0

3.0

3.0

0.7

21.0

For contactors and similar devices, the in-rush power ratings should be used as the worst case values when performing power budget calculations. Also, the application engineer must consider the possible combinations of simultaneously energized outputs and calculate the VA ratings accordingly.

The worst case, which uses the largest possible VA load, should be determined when sizing the transformer.

Each controller requires 24 Vac power from an energy-limited

Class II power source. To conform to Class II restrictions (U.S. only), transformers must not be larger than 100 VA. A single transformer can power more than one controller.

GUIDELINES FOR POWER WIRING ARE AS FOLLOWS:

— For multiple controllers operating from a single transformer, the same side of the transformer secondary must be connected to the same power input terminal in each device. The earth ground terminal must be connected to a verified earth ground for each controller in the group (see Fig. 13 on page 11).

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 transformer (U.S. only).

— See Fig. 12 on page 10 for controller power wiring used in UL 1995 equipment (U.S. only).

— Many controllers require all loads to be powered by the same transformer that powers the controller.

— Keep the earth ground connection wire run as short as possible (refer to Fig. 11–Fig. 13 beginning on page 10).

— Do not connect earth ground to the controller’s digital or analog ground terminals (refer to Fig. 11 and Fig.

13).

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

— Unswitched 24 Vac power wiring can be run in the same conduit as the L ON W ORKS ® Bus cable.

— Maintain at least a 3 in. (76 mm) separation between

Triac outputs and L ON W ORKS ® Bus wiring throughout the installation.

Line-Loss

Controllers must receive a minimum supply voltage of 20 Vac.

If long power or output wire runs are required, a voltage drop due to Ohms Law (I x R) line-loss must be considered. This line-loss can result in a significant increase in total power required and thereby affect transformer sizing. The following example is an I x R line-loss calculation for a 200 ft. (61m) run from the transformer to a controller drawing 37 VA and using two 18 AWG (1.0 sq mm) wires.

The formula is:

Loss = [length of round-trip wire run (ft.)] x [resistance in wire (ohms per ft.)] x [current in wire (amperes)]

From specification data:

18 AWG twisted pair wire has a resistance of 6.52 ohms per

1000 feet.

Loss = [(400 ft.) x (6.52/1000 ohms per ft.)] x [(37 VA)/(24V)]

= 4.02 volts

This means that four volts are going to be lost between the transformer and the controller. To assure the controller receives at least 20 volts, the transformer must output more than 24 volts. Because all transformer output voltage levels depend on the size of the connected load, a larger transformer outputs a higher voltage than a smaller one for a given load.

Fig. 10 shows this voltage load dependence.

In the preceding I x R loss example, even though the controller load is only 37 VA, a standard 40 VA transformer is not sufficient due to the line-loss. Looking at Fig. 10, a 40 VA transformer is just under 100 percent loaded (for the 37 VA controller) and has a secondary voltage of 22.9 volts. (Use the lower edge of the shaded zone in Fig. 10 that represents the worst case conditions.) When the I x R loss of four volts is subtracted, only 18.9 volts reaches the controller. This is not enough voltage for proper operation.

In this situation, the engineer has three alternatives:

1.

Use a larger transformer. For example, if an 80 VA model is used, an output of 24.4 volts, minus the four volt lineloss, supplies 20.4V to the controller (see Fig. 10).

Although acceptable, the four-volt line-loss in this example is higher than recommended.

IMPORTANT

No installation should be designed where the line-loss is greater than two volts. This allows for nominal operation if the primary voltage drops to 102 Vac (120 Vac minus 15 percent).

2.

Use heavier gauge wire for the power run. 14 AWG

(2.0 sq mm) wire has a resistance of 2.57 ohms per

1,000 ft. Using the preceding formula results in a lineloss of only 1.58 volts (compared with 4.02 volts). This would allow a 40 VA transformer to be used. 14 AWG

(2.0 sq mm) wire is the recommended wire size for 24

Vac wiring.

3.

Locate the transformer closer to the controller. This reduces the length of the wire run, and the line-loss.

The issue of line-loss is also important in the case of the output wiring connected to the Triac digital outputs. The same formula and method are used. Keep all power and output wire runs as short as practical. When necessary, use heavier gauge wire, a bigger transformer, or install the transformer closer to the controller.

To meet the National Electrical Manufacturers Association

(NEMA) standards, a transformer must stay within the NEMA limits. The chart in Fig. 10 shows the required limits at various loads.

With 100 percent load, the transformer secondary must supply between 23 and 25 volts to meet the NEMA standard. When a purchased transformer meets the NEMA standard DC20-1986, the transformer voltage regulating ability can be considered reliable. Compliance with the NEMA standard is voluntary.

17

16

15

14

21

20

19

18

24

23

22

27

26

25

0 50 100

% OF LOAD

150

M993

200

Fig. 10. NEMA Class 2 transformer voltage output limits.

The Honeywell transformers listed in Table 5 meet the NEMA standard DC20-1986.

Table 5. Honeywell transformers that meet

NEMA standard DC20-1986.

Transformer Type

AT40A

AT72D

AT87A

AK3310 Assembly

VA Rating

40

40

50

100

NOTE: The AT88A and AT92A transformers do not meet the voluntary NEMA standard DC20-1986.

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.

9 63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

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.

NOTES:

— For multiple controllers operating from a single transformer, the same side of the transformer secondary must be connected to the same power input terminal in each controller. Controller configurations will not necessarily be limited to three devices, but the total power draw, including accessories, cannot exceed 100 VA when powered by the same transformer (U.S. only). For

power and wiring recommendations, See “Power” on page 7. The earth ground terminal (terminal 3)

must be connected to a verified earth ground for each controller in the group (see Fig. 13 on page 11).

— All loads 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. 18–Fig. 23 beginning on page 15 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

II restrictions (U.S. only), the transformer must not be larger than 100 VA.

Fig. 11 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 connected with a wire nut. Include a pigtail with this wire group and attach the pigtail to the terminal block.

IMPORTANT

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. 12). 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 L ON W ORKS ® cable.

— Maintain at least a 3 in. (7.6 cm) separation between Triac outputs and L ON W ORKS ® wiring throughout the installation.

Δ P

CONNECT POWER TO

TERMINALS 1 AND 2

TRANSFORMER

COM

24 VAC

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 0

EARTH

GROUND

(TERMINAL 3)

OUTPUT

DEVICE

POWER M23557A

Fig. 11. Power wiring details for one controller per transformer.

Δ P

2 3

1 2 3 4 5 6 7 8 0

3 3 3

1 2 3 4 5 6 7 8 0

1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 0

CONNECT POWER TO

TERMINALS 1 AND 2

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 0

TRANSFORMER

COM

24 VAC

EARTH

GROUND

(TERMINAL 3)

LINE VOLTAGE

GREATER

THAN 150 VAC

1

EARTH

GROUND

OUTPUT

DEVICE

POWER

1 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.

M23558A

Fig. 12. Transformer power wiring details for one controller used in UL 1995 equipment (U.S. only).

More than one controller can be powered by a single transformer. Fig. 13 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 transformer (U.S. only). For power wiring

recommendations, see “Power” on page 7.

63-2685—03 10

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

Δ P

2 3

1 2 3 4 5 6 7 8 0

3 3 3

1 2 3 4 5 6 7 8 0

Δ P

2 3

1 2 3 4 5 6 7 8 0

3 3 3

1 2 3 4 5 6 7 8 0

Δ P

2 3

1 2 3 4 5 6 7 8 0

3 3 3

1 2 3 4 5 6 7 8 0

CONNECT POWER TO

TERMINALS 1 AND 2

120/240

VAC

COM

24 VAC

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 0

EARTH

GROUND (TERMINAL 3)

TRANSFORMER

OUTPUT

DEVICE

POWER

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 0

EARTH

GROUND (TERMINAL 3)

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 0

EARTH

GROUND (TERMINAL 3)

Fig. 13. Power wiring details for two or more controllers per transformer.

M23559A

Communications

Refer to “L ON W ORKS ® Wiring Guidelines,” form 74-2865, for a complete description of L ON W ORKS ® Bus network topology rules and approved cable types.

Honeywell provided cable types for L ON W ORKS ® Bus communications wiring are Level IV 22 AWG (0.34 sq mm) plenum or non-plenum rated unshielded, twisted pair, stranded conductor wire.

• For non-plenum areas, U.S. part AK3798 (single-pair stranded) can be used.

• In plenum areas, U.S. part AK3797 (single-pair stranded) or

U.S. part AK3799 (two-pair stranded) can be used.

Contact Echelon Corp. Technical Support for the recommended vendors of Echelon approved cables.

Communications wiring can be run in a conduit, if needed, with non-switched 24 Vac or sensor wiring. If a longer L ON W ORKS ®

Bus network is required, a Q7751A,B router (configured as a repeater) can be added to extend the length of the

L ON W ORKS ® Bus. Each network segment can have a maximum of one repeater.

Pull the cable to each controller on the L ON W ORKS ® Bus and connect to the controller’s communication terminals 7 and 8.

(See Table 6 on page 13 and Table 7 on page 13, and Fig. 16 on page 14 for location of terminals 7 and 8.)

NOTE: Connection for operator access to the L ON W ORKS ®

Bus is provided by plugging the Serial L ON T ALK ®

Adapter (SLTA) connector into the L ON W ORKS ® Bus jack (see Fig. 16 on page 14).

IMPORTANT

Notes on communications wiring:

• All field wiring must conform to local codes and ordinances (or as specified on installation drawings).

• Do not bundle device output wires with sensor, digital input or communications L ON W ORKS ® Bus wires.

• Do not use different wire types or gauges on the same L ON W ORKS Bus segment. The step change in line impedance characteristics causes unpredictable reflections on the L ON W ORKS ® Bus.

• In noisy (high EMI) environments, avoid wire runs parallel to noisy power cables, motor control centers, or lines containing lighting dimmer switches. Keep at least 3 in. (76 mm) of separation between noisy lines and the L ON W ORKS ® Bus cable.

• The theoretical limit for each L ON W ORKS ® Bus segment is 60 controllers. Up to 120 controllers can be configured when a repeater is used, and the bus must be either singly or doubly terminated. Actual installations may have a lower limit depending on the devices connected.

• The singly terminated bus must have one 209541B

FTT Termination Module for T tap or Star configurations.

• The doubly terminated bus must have two 209541B

FTT Termination Modules, one at each end of the daisy chain (Bus style) wiring run. Note that the

Q7751A,B router (configured as a repeater) has onboard terminating networks that can be jumper- selected on each segment.

• Make sure that neither of the L ON W ORKS ® Bus wires are grounded.

NOTE: If a 209541B Termination Module is required at the controller, connect two of the three termination module wires to the L ON W ORKS ® Bus terminals 7 and

8, which are labeled Net-1 and Net-2, on the controller. Selecting the appropriate two wires depends on the L ON W ORKS ® Bus network topology.

Refer to the “L ON W ORKS ® Bus Wiring Guidelines,” form 74-2865, and the “FTT Termination Module

Installation Instructions,” form 95-7554. For example, on a doubly terminated daisy-chained bus topology, where controllers are on either end of an L ON W ORKS ®

Bus wire run, mount the termination module on the appropriate terminals, as shown in Fig. 14.

11 63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

PVL6436AS

2 3

1 2 3 4 5 6 7 8 0

3 3 3

1 2 3 4 5 6 7 8 0

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

NOTE: ALL LONWORKS

®

CONNECTIONS ARE MADE TO:

NET-1 NET-2

PVL6438NS PVL6436AS

2 3

1 2 3 4 5 6 7 8 0

3 3 3

1 2 3 4 5 6 7 8 0

2 3

1 2 3 4 5 6 7 8 0

3 3 3

1 2 3 4 5 6 7 8 0

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6 AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

SBUS1 SBUS2

1 2 3 4 5 6 7 8

1

DO-3 DO-4 DO-6 COM

0 1

1

9 2 3 4 5 6 7 8 0

SBUS1 SBUS2

1 2 3 4 5 6 7 8

1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

1 1 1 1 1 1 1 1 2

9 0 1 2 3 4 5 6 7 8 0

SBUS1 SBUS2

1 2 3 4 5 6 7 8

1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

1 1 1 1 1 1 1 1 2

9 0 1 2 3 4 5 6 7 8 0

BROWN ORANGE

PART NO. 209541B

TERMINATION

MODULE

PART NO. 209541B

TERMINATION

MODULE

BROWN

ORANGE

M23560B

Fig. 14. Termination modules (L ON W ORKS ® daisy chain connections).

Wiring Method

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 terminal, 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. 15).

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:

1.

Strip 1/2 in. (13 mm) insulation from the conductor.

2.

Cut a 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. 15).

4.

Cut the twisted end of the wires to 3/16 in. (5 mm) before inserting them into the terminal and tightening the screw.

5.

Pull on each wire in all terminals to check for good mechanical connection.

1.

STRIP 1/2 IN. (13 MM)

FROM WIRES TO

BE ATTACHED AT

ONE TERMINAL.

1/2

(13)

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.

M17207

Fig. 15. Attaching two or more wires at terminal blocks.

Wiring Details

Each controller is shipped with the digital outputs, which switch the 24 Vac to the load (High Side).

The three analog outputs (AO) are used to control modulating heating, cooling and economizer equipment. Any AO may be used as a digital output, as follows:

— False (0%) produces 0 Vdc, (0 mA)

— True (100%) produces the maximum 11 Vdc (22 mA)

The wiring connection terminals described in Table 6 and 7 are shown in Fig. 16 and Fig. 17 starting on page 14.

63-2685—03 12

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

Table 6. Description of wiring terminal connections for

PUL6438S, PVL6436AS, and PVL6438NS.

Terminal Label Connection

7

8

4

5

6

1

2

3

18

19

20

14

15

16

17

9

10

11

12

13

COM

DO-5

DO-6

COM

DO-7

DO-8

COM

INPUT POWER & GROUND

24 Vac

24 Vac COM

24 Vac Power

24 Vac Power

EGND Earth Ground

SHLD

SBUS 1

SBUS 2

Shield

Sylk

Sylk

NETWORK CONNECTIONS

NET-1

NET-2

L ON W ORKS ® communications

L ON W ORKS ® communications

DIGITAL OUTPUTS a

Digital Output DO-1

DO-2

COM

DO-3

DO-4

Digital Output

Common

Digital Output

Digital Output

Common

Digital Output

Digital Output

Common

Digital Output

Digital Output

Common

ANALOG OUTPUTS b

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

AO-1

COM

AO-2

AO-3

COM

Analog Output

Common

Analog Output

Analog Output

DI-1

DI-2

COM

DI-3

DI-4

20 Vdc

UI-1

COM

Common

DIGITAL INPUTS c

Digital Input

Digital Input

Common

Digital Input

Digital Input

ATTACHED DEVICE(S) POWER

20 Vdc Power

UNIVERSAL INPUTS

Universal Input

Common

UI-2

UI-3

COM

UI-4

Universal Input

Universal Input

Common

Universal Input

38

39

40

UI-5

COM

UI-6

Universal Input

Common

Universal Input a b c

For the PVL6436AS controller ONLY, terminals 18, 19, and 20 (DO7,

DO8, & COM) are not present. The actuator is internally hardwired to these terminals.

Analog outputs may be configured as digital outputs and operate as follows:

– False (0%) produces 0 Vdc, (0 mA)

– True (100%) produces the maximum 11 Vdc (22 mA)

Digital inputs: Open circuit = False; Closed circuit = True

Table 7. Description of wiring terminal connections for

PUL1012S, PUL4024S, PVL0000AS, PVL4022AS, and

PVL4024NS.

7

8

9

10

11

12

3

4

5

6

1

2

Terminals,

PUL4024S,

PVL4024NS

Terminals,

PVL4022AS a

Terminals,

PUL1012S

Terminals,

PVL0000AS a

INPUT POWER & GROUND

Label

1

2

3

4

5

6

1

2

3

4

5

1

2

3

4

5

24 Vac

24 Vac

COM

Connection

24 Vac Power

24 Vac Power

EGND Earth Ground

20 Vdc 20 Vdc Power

SBUS 1 Sylk

7

8

NA

NA

NA

NA

6 6 SBUS 2 Sylk

NETWORK CONNECTIONS

7 7

8 8

NET-1 LonWorks® communications

NET-2 LonWorks® communications

DIGITAL OUTPUTS b

NA NA

NA

NA

NA

NA

NA

NA

DO-3

COM

DO-4

COM

Digital Output

Common

Digital Output

Common

13

14

15

13

14

15

13

14

NA

NA

15 NA

ANALOG OUTPUTS c

DO-1

DO-2

COM

Digital Output

Digital Output

Common

16

17

18

16

17

18

16

17

NA

NA

AO-1

COM

NA NA

UNIVERSAL INPUTS

AO-2

Analog Output

Common

Analog Output

19

20

21

22

19

20

21

22

19

20

NA

NA

NA

NA

NA

NA

UI-1*

COM

UI-2

UI-3

Universal Input

Common

Universal Input

Universal Input

23

24

23

24

NA

NA

NA

NA

COM

UI-4

Common

Universal Input b c b d a

For the PVL0000AS and PVL4022AS controllers, DO3 and DO4 are internally hardwired to the actuator.

Digital inputs: Open circuit = False; Closed circuit = True

Analog outputs may be configured as digital outputs and operate as follows:

- False (0%) produces 0 Vdc, (0 mA)

- True (100%) produces the maximum 11 Vdc (22 mA)

Digital inputs: Open circuit = False; Closed circuit = True

UI-1* is a hybrid input. It can be configured as either a DI (fast digital pulse meter) or a UI.

d

IMPORTANT

If the controller is not connected to a good earth ground, the controller's internal transient protection circuitry is compromised and the function of protecting the controller from noise and power line spikes cannot be fulfilled. This could result in a damaged circuit board and require replacement of the controller.

Refer to installation diagrams for specific wiring.

13 63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

All controllers have the terminal arrangements similar to the examples shown in Fig. 16 and Fig. 17 as described in Table

Table 6 on page 13 and Table 7 on this page.

N

EURON

®

SERVICE PIN

The N EURON ® Service Pin pushbutton (when pressed) transmits the Service Message to the network, regardless of the controller’s current mode of operation (see Fig. 16 and Fig.

17).

CAUTION

Equipment Damage Hazard.

Can cause controller damage or failure.

Do not use any metal object to press the N

EURON

®

Service Pin. Use a plastic rod or wood device (such as a pencil with the lead broken off) to press the pin. Using a metal object can damage the circuitry of the controller.

LONWORKS BUS CONVENIENCE JACK

The L ON W ORKS Bus connection is provided by plugging the

Serial L ON T ALK

®

Adapter (SLTA) connector into the

L ON W ORKS ® Bus Jack (see Fig. 16 and Fig. 17).

TERMINALS 21-40

1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 0

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

SBUS1 SBUS2

1 2 3 4 5 6 7 8

TERMINALS 1-8

LONWORKS ® BUS JACK

(LABELLED SRV JCK)

9 0 1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

2 3 4 5 6 7 8 0

TERMINALS 9-20

NEURON ® SERVICE PIN

(LABELLED SRV PIN)

M23561B

Fig. 16. Controller Terminal Connections, N

EURON

® Service

Pin, & LONWORKS® Bus Jack for the PUL6438S,

PVL6436AS, and PVL6438NS (PVL6438NS shown).

TERMINALS 13-24

1 1 1 1 1 1 1 2 2 2 2 2

3 4 5 6 7 8 9 0 1 2 3 4

1 1

1 2 3 4 5 6 7 8 9 0 1 2

TERMINALS 1-12

LONWORKS ® BUS JACK (LABELLED SRV JACK)

NEURON® SERVICE PIN (LABELLED SRV PIN)

M28650

Fig. 17. Controller terminal connections, NEURON®

Service Pin and LONWORKS® Bus Jack for the PUL1012S,

PUL4024S, PVL0000AS, PVL4022AS, and PVL4024NS

(PVL4024NS shown).

Wiring Applications (Examples)

Fig. 18–Fig. 24, beginning on page 15, illustrate controller wiring for the following configurations.

• Typical controller wiring for VAV application using the TR23

Wall Module and a C7770A Air Temperature Sensor (see

Fig. 18 on page 15).

• Typical controller wiring for VAV application with staged reheat (see Fig. 19 on page 16).

• Typical controller wiring for PWM reheat and PWM peripheral heat valve actuator (see Fig. 20 on page 17).

• Typical controller wiring for AHU application (see Fig. 21 on page 18).

• Typical controller wiring for 4 to 20 mA enthalpy sensors and digital inputs (see Fig. 22 on page 19).

• Typical controller wiring for 4 to 20 mA heating, cooling, and model ML6161 floating motor control (see Fig. 23 on page 20).

• Typical controller wiring for a pneumatic transducer, model

RP7517B (see Fig. 24 on page 21).

63-2685—03 14

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

AIR FLOW

PICKUP

WINDOWS CONTACTS

(CONTACTS CLOSED

EQUALS WINDOW CLOSED)

OCCUPANCY SENSOR

(CONTACTS CLOSED

EQUALS OCCUPIED)

3 2

COM

3

Δ

P DI-2 DI-3

UI-4

AO-1

DI-1

UI-1

UI-2

COM UI-3

COM

C7770A

AIR

TEMPERATURE

SENSOR

1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 0

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

SBUS1 SBUS2

1 2 3 4 5 6 7 8 9

1 1 1 1 1 1 1 1 2

0

1

1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

2 3 4 5 6 7 8 0

-

24 VAC

24 VAC

COM

1

2

L ON W ORKS -BUS

L ON W ORKS -BUS

COM

DO-2

DO-1

COM

DO-6

DO-5

COM

DO-4

DO-3 SERIES OR PA

12 11 10 9 8 7 6 5 4 3 2 1

REHEAT STAGE 3

REHEAT STAGE 2 (OR CLOSE)

REHEAT STAGE 1 (OR OPEN)

TR23-H

ONLY

DIP

SWITCH

4

S1

ON ON DIP SWITCH S2

SW1 SW2

ON

SW1 SW2

SW1 SW2 SW3

DO NOT CHANGE

THIS SWITCH

POSITION.

DIP SWITCH S3

(TR23 AND TR24

ONLY.)

DAMPER CLOSE

DAMPER OPEN

ML6161 DAMPER ACTUA

1

2

EARTH GROUND WIRE LENGTH SHOULD BE HELD TO A MINIMUM. USE THE HEAVIEST GAUGE WIRE AVAILABLE, UP TO 14 AWG (2.O MM 2 ) WITH A MINIMUM

OF 18 AWG (1.O MM 2 ) FOR EARTH GROUND WIRE.

TO ASSURE PROPER ELECTRICAL CONTACT, WIRES MUST BE TWISTED TOGETHER BEFORE INSERTION INTO THE TERMINAL BLOCK.

3 CONTACTS MUST BE SUITABLE FOR DRY SWITCHING, 5V AT 10 mA. USE SEALED TYPE, GOLD FLASHED OR PIMPLED CONTACTS.

4 DIP SWITCH S1 FOR HUMIDITY MODELS ONLY. SEE TR23 INSTALLATION INSTRUCTIONS, FORM NO. 62-0267, FOR CONFIGURATION DETAILS.

M29753

Fig. 18. Controller wiring diagram (model PVL6438NS shown) for typical VAV application, using the TR23 wall module and a C7770A air temperature sensor. (For note 2, refer to Fig. 15.)

15 63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

AIR FLOW

PICKUP

Δ

P

WINDOWS CONTACTS

(CONTACTS CLOSED

EQUALS WINDOW CLOSED)

OCCUPANCY SENSOR

(CONTACTS CLOSED

EQUALS OCCUPIED)

3 2

COM

3

DI-2

DI-3

AO-1 UI-3

DI-1

UI-1

UI-2

COM

2 2 2 2 2 2 2 2 3 3 3

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

SBUS1 SBUS2

1 2 3 4 5 6 7 8 9 0 1

DO-3 DO-4 DO-6 COM

1

COM +

24 VAC

COM

1

2

DO-2

DO-1

DO-3

STAGE 3

STAGE 2

12 11 10 9 8 7 6 5 4 3 2 1

L ON W ORKS -BUS

L ON W ORKS -BUS

STAGE 1

1

2

3

TR23-H

ONLY

DIP

SWITCH

S1

4

ON

SW1 SW2

ON

DIP SWITCH S2

ON

SW1 SW2

DO NOT CHANGE

THIS SWITCH

POSITION.

DIP SWITCH S3

(TR23 AND TR24

ONLY.)

LINE

POWER

SW1 SW2 SW3

EARTH GROUND WIRE LENGTH SHOULD BE HELD TO A MINIMUM. USE THE HEAVIEST GAUGE WIRE AVAILABLE, UP TO 14 AWG (2.O MM 2

MINIMUM OF 18 AWG (1.O MM 2 ), FOR EARTH GROUND WIRE.

) WITH A

TO ASSURE PROPER ELECTRICAL CONTACT, WIRES MUST BE TWISTED TOGETHER BEFORE INSERTION INTO THE TERMINAL BLOCK.

CONTACTS MUST BE SUITABLE FOR DRY SWITCHING, 5V AT 10 mA. USE SEALED TYPE, GOLD FLASHED OR PIMPLED CONTACTS.

4 DIP SWITCH S1 FOR HUMIDITY MODELS ONLY. SEE TR23 INSTALLATION INSTRUCTIONS, FORM NO. 62-0267, FOR CONFIGURATION DETAILS.

M29755

Fig. 19. Controller wiring diagram (model PVL6436AS shown) for typical VAV application with staged reheat.

(For note 2, refer to Fig. 15.)

63-2685—03 16

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 0

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

24 VAC

24 VAC

COM

SBUS1 SBUS2

1 2 3 4 5 6 7 8

1

9 0 1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

2 3 4 5 6 7 8 0

ML7984B

PWM VALVE ACTUATOR

REHEAT

VALVE ACTUATOR

4

1 2 3 4

ON

OFF

3

ML7984B

CONFIGURATION

DIP SWITCHES

(LOCATED ADJACENT

TO THE INPUT

TERMINAL BLOCK)

PWM (H 24 V

T6 T5 C B W R

DO-3

2

PERIPHERAL HEAT

VALVE ACTUATOR

PWM VALVE ACTUATOR

4

2

PWM (H 24 V

T6 T5 C B W R

2

DO-2

DO-1

4

24 VAC

24 VAC COM

1

2

3

4

EARTH GROUND WIRE LENGTH SHOULD BE HELD TO A MINIMUM.USE THE HEAVIEST GAUGE WIRE AVAILABLE, UP

TO 14 AWG (2.O MM 2 ) WITH A MINIMUM OF 18 AWG (1.O MM 2 ), FOR EARTH GROUND WIRE.

TO ASSURE PROPER ELECTRICAL CONTACT, WIRES MUST BE TWISTED TOGETHER BEFORE INSERTION INTO THE TERMINAL BLOCK.

TURN POWER OFF BEFORE SETTING THE DIP SWITCHES.

MAKE SURE ALL TRANSFORMER/POWER WIRING IS AS SHOWN: REVERSING TERMINATIONS WILL RESULT IN EQUIPMENT

MALFUNCTION. M23573B

Fig. 20. Controller wiring diagram (model PUL6438S shown) for typical PWM reheat and PWM peripheral heat valve actuator. (For note 2, refer to Fig. 15.)

NOTE: Make sure to set the Configuration DIP Switch as shown in Fig. 20. Switches 1 through 3 set the timing of the ML7984B valve actuator to match the controller outputs (0.1 second minimum with a maximum time of

25.6 seconds). Switch 4 determines the action of the actuator (Off = Direct Acting, On = Reverse Acting).

17 63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

20 VDC

DI-1

20 VDC

UI-5

UI-1

COM

UI-2

AO-1

2 2 2 2 2 2 2 2 3 3 3

UI-3

499

COM

3

UI-4

499

2

COM

UI-6

OUTDOOR

ENTHALPY

RETURN

ENTHALPY

DISCHARGE

AIR TEMP

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

FAN

SBUS1 SBUS2

1 2 3 4 5 6 7 8

1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

1 1 1 1 1 1 1 1 2

9 0 1 2 3 4 5 6 7 8 0

+

1

24 VAC

-

24 VAC

COM

2

COM

DO-8

1

L ON W ORKS -BUS

COM

DO-4

DO-3

COM

HEAT 1

HEAT 2

L ON W ORKS -BUS

12

TR23-H

ONLY

11 10 9 8 7 6 5 4 3 2 1

DIP

SWITCH

S1

4

ON

DIP SWITCH S2

ON DO-2

SW1 SW2

ON

SW1 SW2

DO-1

SW1 SW2 SW3

DO NOT

CHANGE

THIS

SWITCH

POSITION.

DIP

SWITCH

S3 (TR23

AND TR24

ONLY.)

COMP 1

COMP2

EARTH GROUND WIRE LENGTH SHOULD BE HELD TO A MINIMUM. USE THE HEAVIEST GAUGE WIRE AVAILABLE, UP TO

14 AWG (2.O MM 2 ) WITH A MINIMUM OF 18 AWG (1.O MM 2 ), FOR EARTH GROUND WIRE.

2 TO ASSURE PROPER ELECTRICAL CONTACT, WIRES MUST BE TWISTED TOGETHER BEFORE INSERTION INTO THE

TERMINAL BLOCK.

3

4

ANALOG OUTPUTS FROM SENSOR ARE 4 TO 20 mA SIGNALS. A 499 OHM 1% TOLERANCE (OR BETTER) PRECISION

RESISTOR IS REQUIRED TO DRIVE THIS AND OTHER 4 TO 20 mA SIGNAL DEVICES. PLACE THIS RESISTOR AS CLOSE

AS POSSIBLE TO THE DRIVEN DEVICE.

DIP SWITCH S1 FOR HUMIDITY MODELS ONLY. SEE TR23 INSTALLATION INSTRUCTIONS, FORM NO. 62-0267,

FOR CONFIGURATION DETAILS.

M29756

Fig. 21. Controller wiring diagram (model PUL6438S shown) for typical AHU application. (For note 2, refer to Fig. 15.)

63-2685—03 18

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

OCCUPANCY SENSOR

(CONTACTS CLOSED

EQUALS OCCUPIED)

WINDOWS CONTACTS

(CONTACTS CLOSED

EQUALS WINDOW CLOSED)

AO-1

DI-1

COM

DI-2

2

DI-3

COM

UI-1

20 VDC

20 VDC

UI-5

UI-3

499

COM

UI-2

3

UI-4

499

2

COM

UI-6

OUTDOOR

ENTHALPY

RETURN

ENTHALPY

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

DISCHARGE

AIR TEMP

FAN

+ 24 VAC

-

24 VAC

COM

SBUS1 SBUS2

1 2 3 4 5 6 7 8

1

2

9

1 1 1 1 1 1 1 1 2

0

1

1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

2 3 4 5 6 7 8 0

COM

DO-8

COM

DO-4

DO-3

COM

HEAT 1

L ON W ORKS -BUS

L ON W ORKS -BUS

HEAT 2

12 11 10 9 8 7 6 5 4 3 2 1

COMP 1

DO-2

1

TR23-H

ONLY

DIP

SWITCH

S1

ON

DIP SWITCH S2

ON

DO-1

COMP2

4

SW1 SW2

ON

SW1 SW2

DO NOT CHANGE

THIS SWITCH

POSITION.

DIP SWITCH S3

(TR23 AND TR24

ONLY.)

SW1 SW2 SW3

EARTH GROUND WIRE LENGTH SHOULD BE HELD TO A MINIMUM. USE THE HEAVIEST GAUGE WIRE AVAILABLE, UP TO 14 AWG (2.O MM 2

WITH A MINIMUM OF 18 AWG (1.O MM 2 ), FOR EARTH GROUND WIRE.

)

2 TO ASSURE PROPER ELECTRICAL CONTACT, WIRES MUST BE TWISTED TOGETHER BEFORE INSERTION INTO THE TERMINAL BLOCK.

3 ANALOG OUTPUTS FROM SENSOR ARE 4 TO 20 mA SIGNALS. A 499 OHM 1% TOLERANCE (OR BETTER) PRECISION RESISTOR IS

REQUIRED TO DRIVE THIS AND OTHER 4 TO 20 mA SIGNAL DEVICES. PLACE THIS RESISTOR AS CLOSE AS POSSIBLE TO THE DRIVEN

DEVICE.

4 DIP SWITCH S1 FOR HUMIDITY MODELS ONLY. SEE TR23 INSTALLATION INSTRUCTIONS, FORM NO. 62-0267,

FOR CONFIGURATION DETAILS.

M29757

Fig. 22. Controller wiring diagram (model PUL6438S shown) with 4 to 20 mA enthalpy sensors and digital inputs.

(For note 2, refer to Fig. 15.)

19 63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

TWO - OR

THREE-WAY

CHILLER

WATER VALVE

TWO - OR

THREE-WAY

HOT WATER/

STEAM VALVE

SERIES 70

VALVE

ACTUATOR

24

VAC COM

IN-

PUT

SERIES 70

VALVE

ACTUATOR

24

VAC COM

IN-

PUT

AO-3

DI-1

UI-1

COM

UI-2

UI-3

AO-1 AO-2

2 2 2 2 2 2 2 2 3 3 3

COM

UI-6

DISCHARGE

AIR TEMP

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

3

SBUS1 SBUS2

1 2 3 4 5 6 7 8 9 0 1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

2 3 4 5 6 7 8 0

FAN

24

+-

1

24 VAC

COM

1

L

2

ON W ORKS -BUS

COM

COM

DO-4

DO-2

DO-1

DAMPER CLOSED

L ON W ORKS -BUS

12 11 10 9 8 7 6 5 4 3 2

TR23-H

ONLY

1

DIP

SWITCH

S1

4

ON

DIP SWITCH S2

SW1 SW2

ON

ON

SW1 SW2

DO NOT

CHANGE

THIS

SWITCH

POSITION.

DIP

SWITCH

S3 (TR23

AND TR24

ONLY.)

DAMPER OPEN

ML6161 DAMPER ACTUA

SW1 SW2 SW3

EARTH GROUND WIRE LENGTH SHOULD BE HELD TO A MINIMUM. USE THE HEAVIEST GAUGE WIRE AVAILABLE, UP TO 14 AWG (2.O MM 2

WITH A MINIMUM OF 18 AWG (1.O MM 2 ), FOR EARTH GROUND WIRE.

)

2

3

TO ASSURE PROPER ELECTRICAL CONTACT, WIRES MUST BE TWISTED TOGETHER BEFORE INSERTION INTO THE TERMINAL BLOCK.

MAKE SURE ALL TRANSFORMER/POWER WIRING IS AS SHOWN: REVERSING TERMINATIONS WILL RESULT IN EQUIPMENT MALFUNCTION.

4 DIP SWITCH S1 FOR HUMIDITY MODELS ONLY. SEE TR23 INSTALLATION INSTRUCTIONS, FORM NO. 62-0267,

FOR CONFIGURATION DETAILS.

M29758

Fig. 23. Controller wiring diagram (model PUL6438S shown) with 4 to 20 mA heating, cooling, and model ML6161 damper actuator. (For note 2, refer to Fig. 15.)

63-2685—03 20

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

AO1

2

PUL6438S

1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 0

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

+

24 VAC

-

24 VAC

COM

SBUS1 SBUS2

1 2 3 4 5 6 7 8

2B

RP7517B

1

9 0 1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

2 3 4 5 6 7 8 0

PNEUMATIC

VALVE

ACTUATOR

1M

BROWN

BLACK

BLUE

M

1

2

USE 1/4 IN (6 MM) PNEUMATIC TUBING. MINIMUM BRANCH LINE

MUST BE 6 FT. (1.8M) OR LONGER.

TERMINALS 21, 23, AND 24 ARE ANALOG OUTPUTS.

M23570B

Fig. 24. Controller wiring diagram (model PUL6438S shown) for RP7517B pneumatic transducer.

CHECKOUT

Step 1. Check Installation and Wiring

Inspect all wiring connections at the controller terminals, and verify compliance with installation wiring diagrams. If any wiring changes are required, first be sure to remove power from the controller before starting work. Pay particular attention to:

— 24 Vac power connections. Verify that multiple controllers being powered by the same transformer are wired with the transformer secondary connected to the same input terminal numbers on each controller. Use a meter to measure 24 Vac at the appropriate terminals (see Fig. 13 on page 11). 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 transformer (U.S. only).

— Be sure that each controller has terminal 3 wired to a verified earth ground, using a wire run as short as possible with the heaviest gauge wire available, up to 14 AWG (2.0 sq mm) with a minimum of 18 AWG (1.0 sq mm) for each controller in the group (see Fig. 13 on page 11).

— Verify that Triac wiring of the digital outputs to external devices uses the proper load power and 24 Vac common terminal (digital output common terminals) for High-Side switching.

NOTE: All wiring must comply with applicable electrical codes and ordinances or as specified on installation wiring diagrams.

For guidelines for wiring run lengths and power budget, see

“Power” on page 7.

VERIFY TERMINATION MODULE PLACEMENT (MULTIPLE

CONTROLLERS ONLY)

The installation wiring diagrams should indicate the locations for placement of the 209541B termination module(s). See

Fig. 14 on page 12 and refer to the “L ON W ORKS ® Bus Wiring

Guidelines,” form 74-2865, and the “FTT Termination Module

Installation Instructions,” form 95-7554.

Correct placement of the termination module(s) is required for proper L ON W ORKS ® Bus communications.

Step 2. Startup

Refer to Fig. 25 and the following text for startup information.

LED

TERMINALS 21-40

1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 0

AO-1 COM AO-2 AO-3 COM DI-1 DI-2 COM DI-3 UI-1 COM UI-2 UI-3 COM UI-4 UI-5 COM UI-6

SBUS1 SBUS2

1 2 3 4 5 6 7 8

TERMINALS 1-8

LONWORKS ® BUS JACK

(LABELLED SRV JCK)

9 0 1

DO-3 DO-4 DO-6 COM DO-7 DO-8 COM

2 3 4 5 6 7 8 0

TERMINALS 9-20

NEURON ® SERVICE PIN

(LABELLED SRV PIN)

M23562B

Fig. 25. LED, service pin, and network connection locations.

BROADCAST THE SERVICE MESSAGE

The Service Message allows a device on the L

ON

W

ORKS

® Bus to be positively identified. The Service Message contains the controller’s Neuron in a building.

®

ID number and node type. This is used to confirm the physical location of a particular Spyder Lon device

• To send the Service Message from the controller, press the

N

EURON

® Service Pin pushbutton on the controller (see Fig.

25 above, and Fig. 16 and Fig. 17 on page 14). This button sends out the Service Message when it is pressed, regardless of the controller’s current mode of operation.

CAUTION

Equipment Damage Hazard.

Can cause controller damage or failure.

Do not use any metal object to press the N EURON ®

Service Pin. Use a plastic rod or wood device (such as a pencil with the lead broken off) to press the pin. Using a metal object can damage the circuitry of the controller.

CONTROLLER STATUS LED:

The LED on the front of the controller provides a visual indication of the status of the device. When the controller receives power, the LED appears in one of the following allowable states, as described in Table 8.

21 63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

Table 8. Status LED states.

LED State

OFF

ON

Very Slow Blink

(continuous)

Slow Blink

(continuous)

Medium Blink

(continuous)

Fast Blink

(continuous)

Blink Rate

Not applicable

ON steady; not blinking

1 second ON,

1 second OFF

0.5 second ON,

0.5 second OFF

Status or Condition

No power to processor,

LED damaged, low voltage to board, or controller damaged.

Processor and/or controller is not operating.

Controller is operating normally.

Controller alarm is active, controller in process of download, or controller lost its configuration.

0.25 second ON,

0.25 second OFF

Controller firmware is loading.

0.10 second ON,

0.10 second OFF

Controller is in manual mode under control of the

PC-based software tool.

Step 3. Checkout Completion

At this point the controller is installed and powered. To complete the checkout, the N IAGARA F RAMEWORK ® application

(run on a PC) is used to configure the I/O and functions of the controller. Refer to the Programming Tool User Guide, form no.

63-2662, for controller configuration and programming details.

CONTROLLER REPLACEMENT

There are no serviceable or repairable parts inside the controller.

WARNING

Fire, Explosion, or Electrical Shock Hazard.

Can cause severe injury, death or property damage.

Do not attempt to modify the physical or electrical characteristics of this device in any way. Replace the controller if troubleshooting indicates a malfunction.

WARNING

Electrical Shock Hazard.

Can cause severe injury, death or property damage.

Disconnect power supply before beginning controller replacement to prevent electrical shock or equipment damage.

Terminal Block Removal

To simplify controller replacement, all terminal blocks are designed to be removed with the wiring connections intact and then re-installed on the new controller. See Fig. 26 and refer to the following procedure:

IMPORTANT

To prevent bending or breaking the alignment pins on longer terminal blocks, insert the screwdriver at several points to evenly and gradually lift up the terminal block.

Insert the screwdriver blade no more than 1/8 in.

(3 mm) to prevent damage to the terminal block alignment pins on the controller circuit board.

SHORT TERMINAL BLOCK LONGTERMINAL BLOCK

M23563

Fig. 26. Removing Terminal Blocks.

1.

Use a thin-bladed screwdriver to evenly raise the terminal block from its alignment pins: a. For short terminal blocks (1 to 5 terminals), insert screwdriver blade in the center of the terminal block and use a back and forth twisting motion to gently raise the terminal block from its alignment pins 1/4 in.

(6.35 mm).

b. For long terminal blocks (6 or more terminals), insert screwdriver blade on one side of the terminal block and gently rotate the blade 1/4 turn. Then, move to the other side of the terminal block and do the same.

Repeat until the terminal block is evenly raised 1/4 in. (6.35 mm) from its alignment pins.

2.

Once the terminal block is raised 1/4 in. (6.35 mm) from its alignment pins, grasp the terminal block at its center

(for long terminal blocks grasp it at each end) and pull it straight up.

Controller Replacement (PVL0000AS,

PVL4022AS, and PVL6436AS)

For PVL0000AS, 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 (See “Terminal Block

Removal” ).

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.

• Gently pull the controller and actuator assembly straight out, until the assembly is clear of the actuator shaft.

5.

Mount the new controller and actuator assembly (See

“Installation” on page 4.).

63-2685—03 22

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

6.

Reconnect the two air flow pickup tubes to the pressure

sensor (See “Piping (PVL0000AS, PVL4022AS,

PVL4024NS, PVL6436AS, and PVL6438NS)” on page 7.).

7.

Replace the terminal blocks:

• Insert each terminal block onto its alignment pins.

• Press straight down to firmly seat it.

• Repeat for each terminal block.

8.

Restore power to the controller.

9.

Perform “Checkout” on page 21.

Controller Replacement (PVL4024NS and PVL6438NS)

Perform the following to replace the PVL4024NS 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.

• See “Terminal Block Removal” on page 22..

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 7).

5.

Mount the new controller.

• See “Installation” on page 4.

6.

Reconnect the two air flow pickup tubes to the pressure

sensor (See “Piping (PVL0000AS, PVL4022AS,

PVL4024NS, PVL6436AS, and PVL6438NS)” on page 7.).

7.

Replace the terminal blocks:

• Insert each terminal block onto its alignment pins.

• Press straight down to firmly seat it.

• Repeat for each terminal block.

8.

Restore power to the controller.

9.

Perform “Checkout” on page 21.

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 blocks (See “Terminal Block

Removal” on page 22.).

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 7).

4.

Mount the new controller (See “Installation” on page 4.).

5.

Replace the terminal blocks:

• Insert each terminal block onto its alignment pins.

• Press straight down to firmly seat it.

• Repeat for each terminal block.

6.

Restore power to the controller.

7.

Perform “Checkout” on page 21.

23 63-2685—03

SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

Automation and Control Solutions

Honeywell International Inc.

1985 Douglas Drive North

Golden Valley, MN 55422

Honeywell Limited-Honeywell Limitée

35 Dynamic Drive

Toronto, Ontario M1V 4Z9 customer.honeywell.com

® U.S. Registered Trademark

© 2009 Honeywell International Inc.

63-2685—03 M.S. Rev. 11-09

Printed in U.S.A.

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