Honeywell Food Saver PUL1012S User Manual

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)  
®
LONMARK -compliant devices designed to control HVAC  
equipment. These controllers provide many options and  
advanced system features that allow state-of-the-art  
commercial building control. Each controller is programmable  
and configurable through software.  
These controllers are for use in VAV (Variable Air Volume) and  
Unitary HVAC control applications. Each controller contains a  
host micro controller to run the main HVAC application and a  
second micro controller for LONWORKS® network  
communications. Each controller has flexible, universal inputs  
for external sensors, digital inputs, and a combination of  
analog and digital Triac outputs. The eight models are  
described in Table 1. The photo to the left is the model  
PVL6436AS, which includes the actuator.  
Table 1. Controller configurations.  
Velocity  
Pressure  
Sensor  
Universal  
Inputs  
(UI)  
Digital  
Inputs  
(DI)  
Analog  
Outputs  
(AO)  
Digital  
Outputs  
(DO)  
Series 60  
Floating  
Actuator  
Controller  
Model  
Programmable  
Type  
(Microbridge)  
a
PUL1012S  
PUL4024S  
Unitary  
Unitary  
0
0
1
2
2
4
NO  
NO  
NO  
NO  
1
a
4
PUL6438S  
PVL0000AS  
PVL4022AS  
Unitary  
VAV  
6
0
4
0
0
3
0
2
8
0
2
NO  
YES  
YES  
NO  
YES  
YES  
a
VAV  
4
a
PVL4024NS  
VAV  
0
2
4
YES  
NO  
4
PVL6436AS  
PVL6438NS  
VAV  
VAV  
6
6
4
4
3
3
6
8
YES  
YES  
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® LONWORKS® Network, using the FTT-10A LONWORKS® interface, and is  
LONMARK® compliant.  
Controllers are field-mountable to either a panel or a DIN rail.  
62-0287—03  
 
SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS  
Mounting Actuator onto Damper Shaft (PVL0000AS,  
PVL4022AS, and PVL6436AS )  
DAMPER  
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.  
DAMPER SHAFT  
ROTATES  
CLOCKWISE  
TO OPEN  
M23569  
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).  
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  
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.  
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.  
3. If the damper rotates counterclockwise (CCW) to open,  
and the angle of the damper open-to-closed is 90 degrees:  
a. Manually open the damper fully (rotate counter-  
clockwise).  
b. Using the Declutch button, rotate the universal shaft  
adapter fully counterclockwise.  
c. Mount the actuator to the damper box and shaft.  
d. Tighten the two bolts on the centering clamp (8 mm  
wrench; 70.8–88.5 lb-in. [8–10 Nm] torque). When  
the actuator closes, the damper rotates CW  
90 degrees to fully close.  
TYPE A DAMPER  
4. If the damper rotates counterclockwise (CCW) to open,  
and the angle of the damper open-to-closed is 45 or  
60 degrees:  
AIR  
FLOW  
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.  
CW TO OPEN, CCW TO CLOSE  
TYPE B DAMPER  
AIR  
FLOW  
CCW TO OPEN, CW TO CLOSE  
M2067B  
Fig. 3. Determining the rotation direction (CW or CCW)  
for damper opening.  
3
62-0287—03  
 
SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS  
Mount Controller  
DEPTH IS 2-1/4 (57)  
4-13/16 (122)  
4-1/8 (105)  
4-13/16 (122)  
4-1/8 (105)  
NOTE: The controller may be wired before mounting to a  
panel or DIN rail.  
1
3
1
4
1
5
1
6
1
7
1
8
1
9
2
0
2
1
2
2
2
3
2
4
1
3
1
1
5
1
6
1
7
1
8
1
9
2
0
2
1
2
2
2
3
2
4
4
Terminal blocks are used to make all wiring connections to the  
controller. Attach all wiring to the appropriate terminal blocks  
6-1/4  
(159)  
6-1/4  
(159)  
5-7/8  
(149)  
5-7/8  
(149)  
See Fig. 4 to Fig. 7 for panel mounting dimensions. See Fig. 8  
on page 5 for DIN rail mounting.  
1
1
1
2
1
1
1
2
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
0
10-5/16 (262)  
8-5/16 (211)  
1-55/64  
(47)  
3/16 (4.5) PANEL MOUNTING HOLE (4X)  
NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.  
6-29/64 (164)  
M28649  
Fig. 5. Panel mounting — controller dimensions in inches  
(mm) for PUL1012S, PUL4024S, and PVL4024NS only  
(PUL4024S and PVL4024NS shown).  
2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4  
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0  
5-3/4  
(146)  
7/16  
(11)  
6-17/64  
(159)  
8-9/32  
(211)  
1-15/16  
(49)  
5-3/64  
(128)  
4-1/8  
(105)  
1 1 1 1 1 1 1 1  
1 2 3 4 5 6 7 8  
9 0 1 2 3 4 5 6 7  
27/32  
(21)  
PANEL MOUNTING HOLE  
(4X) 3/16 IN. (4.5)  
DEPTH IS  
2-1/4 (57)  
1
0
1
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
2
0
9
NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.  
M28647  
Fig. 4. Panel mounting — controller and actuator  
dimensions in inches (mm) for PVL6436AS only.  
6-1/4  
(159)  
6-9/32  
(159)  
5-7/8  
(149)  
1
2
3
4
5
6
7
8
DEPTH IS  
2-1/4 (57)  
3/16 (4.5) PANEL  
MOUNTING HOLE (4X)  
NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.  
M28648  
Fig. 6. Panel mounting — controller and actuator  
dimensions in inches (mm) for PVL0000AS and  
PVL4022AS only (PVL4022AS shown).  
PANEL MOUNTING HOLE  
(4X) 29/64 IN. (12)  
PVL6438NS  
PUL6438S  
2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4  
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0  
2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4  
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0  
5-3/4  
(146)  
5-3/64  
(128)  
5-3/64  
(128)  
5-29/64  
(139)  
5-29/64  
(139)  
1 1 1 1 1 1 1 1 1 1 2  
9 0 1 2 3 4 5 6 7 8 9 0  
1 1 1 1 1 1 1 1 1 1 2  
9 0 1 2 3 4 5 6 7 8 9 0  
1 2 3 4 5 6 7 8  
1 2 3 4 5 6 7 8  
6-29/64 (164)  
6-27/32 (174)  
6-29/64 (164)  
6-27/32 (174)  
DEPTH IS  
2-1/4 (57)  
M23589B  
NOTE: CONTROLLER CAN BE MOUNTED IN ANY ORIENTATION.  
Fig. 7. Panel mounting — controller dimensions in inches (mm) for PUL6438S and PVL6438NS only.  
62-0287—03  
4
 
   
SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS  
NOTES:  
Panel Mounting  
The controller enclosure is constructed of a plastic base plate  
and a plastic factory-snap-on cover.  
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.  
NOTE: The controller is designed so that the cover does not  
need to be removed from the base plate for either  
mounting or wiring.  
Connect the high pressure or upstream tube to the plastic  
restrictor port labeled (+), and the low pressure or  
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.  
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.  
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.  
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.  
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 con-  
troller onto the top of the DIN rail.  
2. Push down and in to snap the two bottom flex connec-  
tors of the controller onto the DIN rail.  
The tubing from the air flow pickup to the control-  
ler should not exceed three feet (0.914 m). Any  
length greater than this will degrade the flow  
sensing accuracy.  
Use caution when removing tubing from a con-  
nector. Always pull straight away from the con-  
nector or use diagonal cutters to cut the edge of  
the tubing attached to the connector. Never  
remove by pulling at an angle.  
TOP TABS  
AIR FLOW  
PICKUP  
CONNECTOR  
TUBING  
DIN RAIL  
RESTRICTOR  
PORT  
RESTRICTOR  
PORT  
ΔP  
2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4  
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0  
BOTTOM FLEX  
CONNECTORS  
M16815  
1 1 1 1 1 1 1 1 1 1 2  
9 0 1 2 3 4 5 6 7 8 9 0  
1 2 3 4 5 6 7 8  
Fig. 8. Controller DIN rail mounting (models PUL1012S,  
PUL4024S, PUL6438S, PVL4024NS, and PVL6438NS).  
M23556A  
Fig. 9. Air flow pickup connections (PVL0000AS,  
PVL4022AS, PVL4024NS, PVL6436AS, and PVL6438NS).  
IMPORTANT  
To remove the controller from the DIN rail, perform the  
following:  
Wiring  
1. Push straight up from the bottom to release the top  
tabs.  
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.  
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.  
Piping (PVL0000AS, PVL4022AS,  
PVL4024NS, PVL6436AS, and PVL6438NS)  
WARNING  
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.  
Electrical Shock Hazard.  
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).  
5
62-0287—03  
 
   
SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS  
NOTES:  
Maintain at least a 3 in. (7.6 cm) separation  
between Triac outputs and LONWORKS® wiring  
throughout the installation.  
For multiple controllers operating from a single  
transformer, the same side of the transformer sec-  
ondary must be connected to the same power  
input terminal in each controller. Controller config-  
urations will not necessarily be limited to three  
devices, but the total power draw, including  
accessories, cannot exceed 100 VA when pow-  
ered by the same transformer (U.S. only). For  
power and wiring recommendations, see “Wiring”  
on page 5 The earth ground terminal (terminal 3)  
must be connected to a verified earth ground for  
each controller in the group (see Fig. 12 on  
page 7).  
ΔP  
2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4  
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0  
CONNECT POWER TO  
TERMINALS 1 AND 2  
1 1 1 1 1 1 1 1 1 1 2  
9 0 1 2 3 4 5 6 7 8 9 0  
1 2 3 4 5 6 7 8  
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. 10–Fig. 12 for wiring  
examples.  
EARTH  
COM  
24 VAC  
GROUND  
(TERMINAL 3)  
TRANSFORMER  
OUTPUT  
DEVICE  
POWER  
M23557A  
Fig. 10. Power wiring details for one controller  
per transformer.  
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.  
ΔP  
22222222233333333334  
12345678901234567890  
Fig. 10 depicts a single controller using one transformer.  
IMPORTANT  
CONNECT POWER TO  
TERMINALS 1 AND 2  
11111111112  
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..  
12345678  
901234567890  
TRANSFORMER  
EARTH  
COM  
GROUND  
(TERMINAL 3)  
IMPORTANT  
24 VAC  
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.  
LINE VOLTAGE  
GREATER  
THAN 150 VAC  
1
OUTPUT  
DEVICE  
POWER  
EARTH  
GROUND  
Screw-type terminal blocks are designed to accept  
up to one 14 AWG (2.0 sq mm) conductor or up to  
two 18 AWG (1.0 sq mm) conductors. More than two  
wires that are 18 AWG (2.0 sq mm) can be con-  
nected with a wire nut. Include a pigtail with this wire  
group and attach the pigtail to the terminal block.  
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. 11. Transformer power wiring details for one  
controller used in UL 1995 equipment (U.S. only).  
IMPORTANT  
More than one controller can be powered by a single  
transformer. Fig. 12 shows power wiring details for multiple  
controllers.  
If the controller is used on Heating and Cooling  
Equipment (UL 1995, U.S. only) and the  
transformer primary power is more than 150 volts,  
connect terminal 2, (the 24 Vac common [24 VAC  
COM] terminal) to earth ground (see Fig. 11). For  
these applications, only one controller can be  
powered by each transformer.  
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 “Wiring” on page 5.  
NOTES:  
Unswitched 24 Vac power wiring can be run in the  
same conduit as the LONWORKS® cable.  
62-0287—03  
6
 
SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS  
ΔP  
ΔP  
ΔP  
2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4  
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0  
2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4  
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0  
2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4  
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0  
CONNECT POWER TO  
TERMINALS 1 AND 2  
1 1 1 1 1 1 1 1 1 1 2  
9 0 1 2 3 4 5 6 7 8 9 0  
1 1 1 1 1 1 1 1 1 1 2  
9 0 1 2 3 4 5 6 7 8 9 0  
1 1 1 1 1 1 1 1 1 1 2  
9 0 1 2 3 4 5 6 7 8 9 0  
1 2 3 4 5 6 7 8  
1 2 3 4 5 6 7 8  
1 2 3 4 5 6 7 8  
EARTH  
GROUND (TERMINAL 3)  
EARTH  
GROUND (TERMINAL 3)  
EARTH  
GROUND (TERMINAL 3)  
COM  
24 VAC  
120/240  
VAC  
TRANSFORMER  
OUTPUT  
DEVICE  
POWER  
M23559A  
Fig. 12. Power wiring details for two or more controllers per transformer.  
Wiring Method  
1.STRIP 1/2 IN. (13 MM)  
1/2  
FROM WIRES TO  
BE ATTACHED AT  
ONE TERMINAL.  
(13)  
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.  
2. TWIST WIRES  
TOGETHER WITH  
PLIERS (A MINIMUM  
OF THREE TURNS).  
NOTE: When attaching two or more wires to the same termi-  
nal, other than 14 AWG (2.0 sq mm), be sure to twist  
them together. Deviation from this rule can result in  
improper electrical contact (see Fig. 13).  
Each terminal can accommodate the following gauges of wire:  
— Single wire: from 22 AWG to 14 AWG solid or stranded  
— Multiple wires: up to two 18 AWG stranded, with 1/4 watt  
wire-wound resistor  
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  
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. 13).  
4. Cut the twisted end of the wires to 3/16 in. (5 mm)  
before inserting them into the terminal and tightening  
the screw.  
Fig. 13. Attaching two or more wires at terminal blocks.  
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):  
5. Pull on each wire in all terminals to check for good  
mechanical connection.  
1. Remove all power from the controller.  
2. Remove the two air flow pickup connections from the  
pressure sensor.  
3. Remove the terminal blocks.  
4. Remove the old controller and actuator assembly from  
its mounting.  
Loosen the two bolts on the actuator clamp to  
release the actuator from the shaft.  
Remove the controller’s mounting screws.  
Gently pull the controller and actuator assembly  
straight out, until the assembly is clear of the  
actuator shaft.  
7
62-0287—03  
 
SPYDER® LON PROGRAMMABLE, VAV/UNITARY CONTROLLERS  
5. Mount the new controller and actuator assembly (see  
6. Reconnect the two air flow pickup tubes to the pressure  
6. Reconnect the two air flow pickup tubes to the pressure  
page 5).  
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.  
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.  
8. Restore power to the controller.  
9. Perform checkout.  
Controller Replacement (PUL1012S,  
PUL4024S, and PUL6438S)  
Controller Replacement (PVL4024NS and  
PVL6438NS)  
Perform the following to replace the PUL1012S, PUL4024S,  
and PUL6438S controllers:  
Perform the following to replace the PV4024NS and  
PVL6438NS controllers:  
1. Remove all power from the controller.  
2. Remove the terminal blocks.  
1. Remove all power from the controller.  
2. Remove the two air flow pickup connections from the  
pressure sensor.  
3. Remove the terminal blocks.  
4. Remove the old controller from its mounting.  
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.  
IMPORTANT  
2. Rotate the top of the controller outwards to release  
the bottom flex connectors (see Fig. 8 on page 5).  
(FOR CONTROLLERS MOUNTED TO A DIN RAIL):  
1. Push straight up from the bottom to release the top  
pins.  
5. Replace the terminal blocks:  
2. Rotate the top of the controller outwards to release  
the bottom flex connectors (see Fig. 8 on page 5).  
Insert each terminal block onto its alignment pins.  
Press straight down to firmly seat it.  
Repeat for each terminal block.  
5. Mount the new controller.  
6. Restore power to the controller.  
7. Perform checkout.  
LON®, LONTALK®, LONWORKS®, and NEURON® are registered trademarks of Echelon® Corporation.  
LONMARK® and the LonMark Logo are trademarks of the LonMark Association.  
NIAGARA FRAMEWORK® and the Niagara framework logo are registered trademarks of Tridium, Inc.  
Automation and Control Solutions  
Honeywell International Inc.  
1985 Douglas Drive North  
Golden Valley, MN 55422  
customer.honeywell.com  
Honeywell Limited-Honeywell Limitée  
35 Dynamic Drive  
Toronto, Ontario M1V 4Z9  
® U.S. Registered Trademark  
© 2009 Honeywell International Inc.  
62-0287—03 K.K. 02-09  
 

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