Honeywell PVL4022AS, PVL4024NS, PVL6438NS, PVL0000AS, PUL6438S User Manual

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Spyder® Lon Programmable, VAV/Unitary Controllers

INSTALLATION INSTRUCTIONS

PRODUCT DESCRIPTION

The PUL1012S, PUL4024S, PUL6438S, PVL0000AS, PVL4022AS, PVL4024NS, PVL6436AS, and PVL6438NS controllers are part of the Excel 10 product line family. The eight controllers are Free Topology Transceiver (FTT) L

ONMARK

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.

Universal

Controller

Model

PUL1012S Unitary

PUL4024S Unitary

PUL6438S Unitary 6 4 3 8 NO NO

PVL0000AS VAV 0 0 0 0 YES YES

PVL4022AS VAV

PVL4024NS VAV

PVL6436AS VAV 6 4 3 6 YES YES

PVL6438NS VAV 6 4 3 8 YES NO

One Universal Input (UI-1*) is user selectable as a fast digital pulse meter.

Each controller communicates via the 78 kbps Echelon® L L

ONMARK® compliant.

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

Programmable

Typ e

Inputs

(UI)

Digital Inputs

(DI)

01 2 NONO

02 4 NONO

0 2 2 YES YES

0 2 4 YES NO

ONWORKS® Network, using the FTT-10A LONWORKS® interface, and is

Analog

Outputs

(AO)

-compliant devices designed to control HVAC

Velocity

Digital

Outputs

(DO)

Pressure

Sensor

(Microbridge)

Series 60

Floating

Actuator

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SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS

WARNING

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: 20 VA maximum; models PUL1012S,

PUL4024S, PUL6438S, PVL4024NS, and PVL6438NS.

Controller and Actuator Load: 21 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 down-

load process, alarms, manual mode, and error conditions

BEFORE 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.

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

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 4 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).

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)

DECLUTCH

BUTTON

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.

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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

M23569

DAMPER SHAFT ROTATES CLOCKWISE TO OPEN

DAMPER

AIR FLOW

CW TO OPEN, CCW TO CLOSE

CCW TO OPEN, CW TO CLOSE

M2067B

TYPE A DAMPER

TYPE B DAMPER

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

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

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.

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). g. When the actuator closes, the damper rotates CCW

either 45 or 60 degrees to fully close.

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 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 (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 lb-in. [3.0–3.5 Nm] torque).

d. Using the Declutch button, rotate the universal shaft

adapter fully counter-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). g. When the actuator closes, the damper rotates CW

either 45 or 60 degrees to fully close.

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