Honeywell PVB6438NS, PVB6435AS, PVB4022AS, PVB0000AS, PVB4024S User Manual

®

Spyder® BACnet
Programmable Controllers

PRODUCT DATA

PRODUCT DESCRIPTION

The PUB and PVB controllers are part of the Spyder family.
These controllers are BACnet MS/TP network 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.

Table 1. Controller configurations.

Controller

Model

PUB1012S Unitary 1 0 1 2 NO NO

PUB4024S Unitary 4 0 2 4 NO NO

PUB6438S Unitary 6 4 3 8 NO NO

PVB0000AS VAV 0 0 0 0 YES YES

PVB4022AS VAV 4 0 2 2 YES YES

PVB4024NS VAV 4 0 2 4 YES NO

PVB6436AS VAV 6 4 3 6 YES YES

PVB6438NS VAV 6 4 3 8 YES NO

Each controller communicates via an EIA-485 BACnet MS/TP communications network, capable of baud rates between 9.6 and

115.2 kbits/s.
Controllers are field-mountable to either a panel or a DIN rail.

Programmable

Type

Universal

Inputs

(UI)

Digital
Inputs

(DI)

The Spyder BACnet controllers require the Spyder BACnet
Programmable Feature to be licensed in the WEBpro
workbench tool and the WEBS AX JACE Controller for
programming and downloading. The Spyder BACnet 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:
PUB6438S-ILC follows all the same Installation Instructions
information as the PUB6438S.

These controllers are for use in VAV (Variable Air Volume),
Unitary and advanced HVAC control applications. Each
controller has flexible, universal inputs for external sensors,
digital inputs, and a combination of analog and digital Triac
outputs. All the models are described in Table 1. The photo to
the left is the model PVB6436AS, which includes the actuator.

Analog

Outputs

(AO)

Digital

Outputs

(DO)

Velocity

Pressure

Sensor

(Microbridge)

Series 60

Floating

Actuator

63-2689-05

SPYDER® BACNET® PROGRAMMABLE 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 PUB1012S,

PUB4024S, PUB6438S, PVB4024NS and PVB6438NS.

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 PVB0000AS, PVB4022AS, PVB4024NS,
PVB6436AS and PVB6438NS):

Minimum 32 ºF (0 ºC); Maximum 122 ºF (50 ºC)

Unitary Operating & Storage Temperature Ambient Rating

(models PUB1012S, PUB4024S and PUB6438S):

Minimum -40 ºF (-40 ºC); Maximum 150 ºF (65.5 ºC)

Relative Humidity: 5% to 95% non-condensing
LED: Provides status for normal operation, controller down-

load process, alarms, manual mode, and error conditions

Velocity Pressure Sensor (models
PVB0000AS, PVB4022AS, PVB4024NS,
PVB6436AS and PVB6438NS)

Operating Range: 0 to 1.5 in. H2O (0 to 374 Pa)

Digital Input (DI) Circuits

Volt age Rati ng: 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

Volt age Rati ng: 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: 0.0 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)

Series 60 Floating Actuator (models
PVB0000AS, PVB4022AS and PVB6436AS)

Rotation Stroke: 95° ± 3° for CW or CCW opening dampers
Torque Ratin g: 44 lb-in. (5 Nm)
Run Time for 90° rotation: 90 seconds at 60 Hz
Operating Temperature: -4 ºF to 140 ºF (-20 to 60 ºC)

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:

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

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

24 hours at 32°F to 100°F (0°C to

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

Sensor

Typ e

20K Ohm
NTC

C7031G

C7041F

PT1000
(IEC751 3850)

a

a

-40 to 199
(-40 to 93

-40 to 120 °F
(-40 to 49

-40 to 250 °F
(-40 to 121

-40 to 199
(-40 to 93

Operating

Range

°

F

°

C)

°

C)

°

C)

°

F

°

C)

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 Environmental and Combustion Controls Sales Office (check white pages of your phone directory).

2. Honeywell Customer Care

1985 Douglas Drive North
Minneapolis, Minnesota 55422-4386

3. http://customer.honeywell.com or http://customer.honeywell.ca
International Sales and Service Offices in all principal cities of the world. Manufacturing in Belgium, Canada, China, Czech
Republic, Germany, Hungary, Italy, Mexico, Netherlands, United Kingdom, and United States.

63-2689—05 2

SPYDER® BACNET® PROGRAMMABLE CONTROLLERS

WARNING

Input

Type

TR23
Setpoint
Potentiometer

Resistive Input Generic 100 Ohms to 100K Ohms

Voltag e
Input

Discrete Input Dry Contact

a

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

Sensor

Typ e

500 Ohm
to
10,500 Ohm

Transducer,
Controller

closure

Operating

Range

-4° DDC to +4° DDC
(-8° DDF to +7° DDF)
or
50 F to 90 F
(10 C to 32 C)

0–10 Vdc

Open Circuit > 3000 Ohms
Closed Circuit < 3000 Ohms

BEFORE INSTALLATION

The controller is available in three 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

The controller must be mounted in a position that allows
clearance for wiring, servicing, removal, connection of the
BACnet MS/TP Molex connector and access to the MS/TP
MAC address DIP switches (see Fig. 15 on page 12).

For the PVB6436AS model, 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 (PVB0000AS, PVB4022AS and PVB6436AS)

PVB0000AS, PVB4022AS and PVB6436AS 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 1­9/16 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. 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.

2. 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 below and Fig. 3 on
page 4 for examples.

UNIVERSAL SHAFT

CLAMPING BOLTS (2)

UNIVERSAL

SHAFT ADAPTER

MECHANICAL

END LIMIT SET

SCREWS (2)

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. 6–Fig. 7 on page 5
for mounting dimensions.

DECLUTCH

BUTTON

M23568

Fig. 1. Series 60 Floating Actuator.

3 63-2689—05

SPYDER® BACNET® PROGRAMMABLE CONTROLLERS

M23569

DAMPER SHAFT
ROTATES
CLOCKWISE
TO OPEN

DAMPER

AIR
FLOW

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.

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 (PVB0000AS, PVB4022AS and
PVB6436AS)

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.

63-2689—05 4

Mounting Actuator Onto Damper Shaft
(PVB0000AS, PVB4022AS and PVB6436AS)

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

3.

4.

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 counterclock-

wise).
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.
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 counterclock-

wise).
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.

SPYDER® BACNET® PROGRAMMABLE CONTROLLERS

NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.

M31532

8-9/32

(211)

1-15/16

(49)

6-9/32

(159)

3/16 (4.5) PANEL

MOUNTING HOLE (4X)

27/32

(21)

4-1/8
(105)

6-1/4
(159)

5-7/8
(149)

DEPTH IS

2-1/ 4 (57)

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

13

14 15 16 17 18 19 20 21 22 23

24

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 3) 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 8).

6-1/4
(159)

5-7/8
(149)

4-13/16 (122)

13 14 15 16 17 18

4-1/8 (105)

19 20 21 22 23 24

DEPTH IS 2-1/4 (57)

6-1/4
(159)

5-7/8
(149)

4-13/16 (122)

14 15 16 17

13

4-1/8 (105)

18

19 20 21 22 23 24

Fig. 5. Panel mounting - controller and actuator
dimensions in inches (mm) for PVB0000AS and

PVB4022AS only (PVB4022AS shown).

10-5/16 (262)

5-3/4
(146)

5-3/64

(128)

123456

NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.

8-5/16 (211)

6-29/64 (164)

2222222223

123456780

78

PANEL MOUNTING HOLE

3

9

11 111111
109 234567

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

333

33

33

34

123456780

1-55/64

(47)

9

DEPTH IS

2-1/ 4 (57)

7/16
(11)

6-17/64

(159)

M29329

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

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

NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.

Fig. 4. Panel mounting - controller dimensions in inches

(mm) for PUB1012S, PUB4024S and PVB4024NS only

(PUB4024S and PVB4024NS shown).

5-3/4

(146)

NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.

Fig. 7. Panel mounting - controller dimensions in inches (mm) for models PUB6438S and PVB6438NS.

5-29/64

(139)

5-3/64

(128)

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

PVB6438NS

2

2 2
1 2 3 4 5 6

7 8

1 2 3 4 5 6

6-29/64 (164)

6-27/32 (174)

M31531

PANEL MOUNTING HOLE

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

2 2 2 2

3 3 3

3 3

2 2 3 3

3 3

3 4

1 2 3 4 5 6

7 8 0 9

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

7 8 0 9

Fig. 6. Panel mounting - controller and actuator

dimensions in inches (mm) for PVB6436AS.

PUB6438S

2

2 2 2 2

3 3 3

2 2 3 3

7 8 0 9

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

3 3

1 2 3 4 5 6

3 3

3 4

7 8 0 9

M29330

2 2

5-3/64

(128)

5-29/64

(139)

1 2 3 4 5 6

DEPTH IS
2-1/ 4 (57)

5 63-2689—05

1 2 3 4 5 6

7 8

6-29/64 (164)
6-27/32 (174)

SPYDER® BACNET® PROGRAMMABLE CONTROLLERS

DIN RAIL

TOP TABS

BOTTOM FLEX
CONNECTORS

M16815

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 (PUB1012S, PUB4024S,
PUB6438S, PVB4024NS and PVB6438NS)

To mount the PUB1012S, PUB4024S, PUB6438S,
PVB4024NS and PVB6438NS controllers 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.

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 (
tube to the restrictor port labeled (

+), and the low pressure or downstream

-). 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)
pressure line (marked as

is recommended for the high

+

) 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 connec-

tor. 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

ΔP

CONNECTOR
TUBING

RESTRICTOR
PORT

2

2 2 2 2

2 2

2 2 3 3

1 2 3 4 5 6

7 8 0 9

3 3 3

3 3

1 2 3 4 5 6

3 3

3 4

7 8 0 9

Fig. 8. Controller DIN rail mounting (models PUB1012S,

PUB4024S, PUB6438S, PVB4024NS and PVB6438NS).

Piping (PVB0000AS, PVB4022AS, PVB4024NS, PVB6436AS and PVB6438NS)

Air flow Pickup

For PVB0000AS, PVB4022AS, PVB4024NS, PVB6436AS and
PVB6438NS, connect the air flow pickup to the two restrictor
ports on the controller (see Fig. 9).

63-2689—05 6

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

M23556A

1 2 3 4 5 6

7 8

Fig. 9. Air flow pickup connections (PVB0000AS,

PVB4022AS, PVB4024NS, PVB6436AS and PVB6438NS).

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. 17–Fig. 23 beginning on page 14 for illustrations of typical
controller wiring for various configurations.

SPYDER® BACNET® PROGRAMMABLE 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 BACnet controller(s) that are required for optimum
system wide 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

• 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. 12 on page 9).

• Half-wave devices and full-wave devices must not use
the same AC transformer. If a Spyder controller will
share its power supply with another device, make
sure the other device utilizes a half-wave rectifier and
that the polarity of the wiring is maintained.

POWER BUDGET CALCULATION EXAMPLE

Table 3 is an example of a power budget calculation for a
typical PVB6436AS controller. While the example is shown for
only this model, the process is applicable for all controller
models.

Table 3. Power budget calculation example.

Device

PVB6436AS
controllers (include
Series 60 Floating
Damper Actuator)

R8242A Contactor
fan rating

D/X Stages 0.0 For example, assume

M6410A Steam
Heating Coil Valve

TOTAL 30.7

VA

Information

Obtained From

9.0 See “Specifications” on
page 2.

21.0

TRADELINE
inrush rating

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

0.7

TRADELINE

0.32A 24 Vac

®

Catalog

®

Catalog,

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. 12 beginning on page 9 for illustrations of
controller power wiring. See Table 4 for VA ratings of various
devices.

Table 4. VA ratings for transformer sizing.

Device Description VA

PVB6436AS

Controller and Actuator 9.0
controllers and
Series 60 Floating
Damper Actuator

PUB6438S or

Controller 5.0
PVB6438NS

ML684 Versadrive Valve Actuator 12.0

ML6161 Damper Actuator, 35 lb-in. 2.2

ML6185 Damper Actuator SR 50 lb-in 12.0

ML6464 Damper Actuator, 66 lb-in. 3.0

ML6474 Damper Actuator, 132 lb-in. 3.0

R6410A Valve Actuator 0.7

R8242A Contactor 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. 12 on page 9).
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. 11 on page 9 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. 12 beginning on page 9).

— Do not connect earth ground to the controller’s digital or

analog ground terminals (refer to Fig. 11 and Fig. 12).

— Unswitched 24 Vac power wiring can be run in the

same conduit as the L

ONWORKS® Bus cable.

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

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

7 63-2689—05

SPYDER® BACNET® PROGRAMMABLE CONTROLLERS

WARNING

27

26

25

24

23

22

21

20

19

18

17

16

15

14

0 50 100 150

% OF LOAD

SECONDARY VOLTAGE

200

M993

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.

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.

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 VA Rating

AT40A 40

AT72D 40

AT87A 50

AK3310 Assembly 100

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.

63-2689—05 8

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.

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”